Replacement of the tail pipe section from the muffler outlet to the rear exit point on a 1966 Chevrolet Corvette with 327ci V8 engine.

Warnings

Tools required

Parts

• Tail pipe assembly × 1 — Use OEM specification or aftermarket equivalent for 1966 Corvette 327 V8
• Muffler clamp (2-piece band clamp) × 1 — 2.5 inch diameter exhaust clamp
• Rubber exhaust hangers × 2 — Replace if deteriorated

Preparation

1. Park vehicle on level, solid ground and engage parking brake.
2. Place wheel chocks in front of and behind both front wheels.
3. Allow exhaust system to cool completely if vehicle was recently operated.
4. Raise rear of vehicle using floor jack at rear differential housing.
5. Place jack stands under frame rails just forward of rear axle housing.
6. Lower vehicle onto jack stands and verify stability before working underneath.

Procedure

1. 1

   Apply penetrating oil to fasteners
   Spray penetrating oil liberally on the muffler-to-tail pipe clamp and all exhaust hanger attachment points. Allow to soak for 10-15 minutes to break down corrosion. On 1966 Corvettes, which typically use a dual exhaust system with a tail pipe on each side, each tail pipe is secured at the muffler outlet with a band clamp and supported by rubber exhaust hangers along its length. Verify the configuration on your specific vehicle.
2. 2

   Locate and inspect tail pipe mounting points
   From underneath the vehicle, identify the tail pipe connection point at the muffler outlet pipe on the side being serviced (the system is typically dual exhaust with a tail pipe on each side). Locate the 2 rubber exhaust hangers that support the tail pipe—one approximately mid-length and one near the rear exit. Inspect the condition of the rubber hangers and the clamp.
3. 3

   Loosen muffler outlet clamp
   Using an SAE socket and ratchet or combination wrench (commonly 9/16"), loosen the nut(s) on the band clamp securing the tail pipe to the muffler outlet pipe. Verify the actual fastener size on your clamp. Remove the bolts completely and separate the two halves of the band clamp. If bolts are severely corroded and break, the clamp will need to be cut off with a hacksaw or cutoff tool.
4. 4

   Remove tail pipe from forward exhaust hanger
   Support the tail pipe with one hand. Using an exhaust hanger removal tool or pry bar, carefully pry the exhaust hanger loop off the rubber isolator mounted to the chassis. Work the metal loop side-to-side while applying gentle pulling force to release it from the rubber grommet. The forward hanger is located approximately 18 inches behind the muffler connection point.
5. 5

   Remove tail pipe from rear exhaust hanger
   Continue supporting the tail pipe weight. Remove the rear exhaust hanger from its rubber isolator using the same pry-and-pull technique. This hanger is located near where the tail pipe exits the body near the rear license plate area on the passenger side.
6. 6

   Remove tail pipe from vehicle
   With both hangers released, slide the tail pipe rearward and away from the muffler outlet pipe, then maneuver it down and out from under the vehicle. The tail pipe will need to be angled and rotated to clear the rear axle housing and suspension components during removal.
7. 7

   Clean muffler outlet pipe
   Using a wire brush, thoroughly clean the outside diameter of the muffler outlet pipe where the tail pipe will connect. Remove all rust, carbon deposits, and old gasket material to ensure a good seal and proper fit for the new tail pipe connection.
8. 8

   Inspect and replace rubber exhaust hangers
   Inspect both rubber exhaust hangers (isolators) mounted to the chassis. If they show cracking, tearing, or significant deterioration, replace them now. New hangers simply pull off the mounting studs on the chassis and press onto the new studs.
9. 9

   Test fit new tail pipe
   Lift the new tail pipe into position and verify proper alignment with the muffler outlet pipe and both hanger locations. The inlet end of the tail pipe should slide over the muffler outlet pipe with approximately 2-3 inches of overlap. Check clearance to chassis, body, and suspension components before final installation.
10. 10

    Install tail pipe onto muffler outlet
    Apply a thin coating of exhaust assembly paste to the muffler outlet pipe if desired (helps with future disassembly and provides additional sealing). Slide the tail pipe inlet fully onto the muffler outlet pipe until it seats against the internal stop or achieves 2-3 inches of overlap. Ensure the tail pipe is oriented correctly for proper exit angle.
11. 11

    Install and hand-tighten muffler clamp
    Position the new 2-piece band clamp around the tail pipe-to-muffler connection joint, centered over the overlap area. Install both clamp bolts with nuts and hand-tighten only. Do not fully tighten yet—final alignment will be performed after hangers are engaged.
12. 12

    Engage forward exhaust hanger
    Lift and position the tail pipe so the forward hanger loop aligns with its rubber isolator. Push the metal loop into the rubber grommet while twisting slightly until it seats fully. The hanger may require significant force—use the weight of the pipe and steady pressure rather than impact.
13. 13

    Engage rear exhaust hanger
    With the forward hanger engaged, lift the rear of the tail pipe into position and engage the rear hanger loop into its rubber isolator using the same technique. Ensure the tail pipe exit is properly positioned relative to the body exit opening before fully seating this hanger.
14. 14

    Align tail pipe and check clearances
    With both hangers engaged, verify the tail pipe has adequate clearance (minimum 0.5 inches) from all chassis components, body panels, suspension parts, and the rear axle housing. Adjust alignment as needed by rotating the pipe at the muffler connection before final tightening. Check that the tail pipe exits properly through or near the body cutout on the passenger side rear.
15. 15

    Tighten muffler clamp to specification
    Using an SAE socket and ratchet (commonly 9/16"), tighten the clamp nut(s) evenly. If two are present, tighten in an alternating pattern. Tighten to snug, then continue tightening each bolt an additional half-turn to compress the clamp and secure the connection. The clamp should compress evenly around the joint without deforming the pipe.

Reassembly

1. Perform final visual inspection of all connections and clearances before lowering vehicle.
2. Raise vehicle slightly with floor jack, remove jack stands, and carefully lower vehicle to ground.
3. Remove wheel chocks.

Verification

• Start engine and allow to idle. Listen for exhaust leaks at the tail pipe-to-muffler connection—there should be no hissing or popping sounds.
• Walk to rear of vehicle and verify exhaust is exiting properly from the tail pipe outlet.
• With engine running, visually inspect the tail pipe for excessive movement or vibration—it should be stable with only minor movement from exhaust pulses.
• After a short test drive, re-inspect all clamp bolts and hanger connections for any loosening or shifting.
• Check clearances again after vehicle settles under its own weight to ensure no contact with chassis or body components.

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