Exhaust Pipe - Rear Section

Remove and replace the rear exhaust section on a 1992 Dodge Viper 8.0L V10, including disconnecting hangers, separating flanged connections, and installing new gaskets.

Warnings

Tools required

Parts

• Rear exhaust section × 1 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust hangers (if damaged) × 1 — Use OEM specification

Preparation

1. Ensure exhaust system is completely cool to the touch
2. Park vehicle on level ground and engage parking brake
3. Raise rear of vehicle using floor jack and support securely on jack stands rated for vehicle weight
4. Spray all exhaust flange bolts and hanger hardware with penetrating oil and allow 15-20 minutes soak time
5. Inspect exhaust routing and hanger locations from underneath to plan removal sequence

Procedure

1. 1

   Support rear exhaust section
   Position floor jack or jack stand under rear muffler section to provide support during removal. The rear section is heavy and will drop when hangers are released.
2. 2

   Remove rear exhaust hangers
   Locate the rubber exhaust hangers supporting the rear section. Using a pry bar or exhaust hanger removal tool, carefully work each hanger off its mounting stud by pulling downward and twisting. The 1992 Viper (RT/10) uses a side-exit exhaust routing through the rocker sills; verify the exact number and location of hangers supporting this section before removal. If hangers are severely deteriorated, they may tear during removal and should be replaced.
3. 3

   Disconnect mid-pipe flange connection
   Locate the flanged connection between the mid-pipe and rear section. Remove the flange bolts connecting the rear section to the mid-pipe using the correct size socket. Verify the exact bolt count and size for this connection against 1992 Viper service documentation before proceeding. Hold opposing nuts if they begin to spin. Once bolts are removed, carefully separate the flanged joint. The gasket may be stuck and require gentle prying with a flat blade screwdriver.
4. 4

   Remove rear exhaust section
   With hangers disconnected and flange separated, carefully lower the rear exhaust section from the vehicle. Guide it past any chassis components or support structures. The section is heavy and awkward; use care to avoid damaging surrounding components or dropping the assembly.
5. 5

   Inspect and clean flange surfaces
   With the rear section removed, inspect the mid-pipe flange for damage, warping, or excessive corrosion. Use a wire brush to thoroughly clean both mating flange surfaces, removing all old gasket material and carbon buildup. Ensure flanges are flat and free of deep pitting that could prevent proper sealing.
6. 6

   Inspect exhaust hangers and mounting points
   Check all rubber exhaust hangers for cracks, tears, or excessive deterioration. Inspect chassis-mounted hanger studs for rust, damage, or looseness. Replace any damaged hangers now before installing new exhaust section.
7. 7

   Prepare new rear exhaust section
   Unpack new rear exhaust section and verify all mounting points, hanger locations, and flange configuration match original. Install new rubber hangers onto the exhaust section pipes if hangers were replaced.
8. 8

   Install new flange gasket
   Position new exhaust flange gasket onto the mid-pipe flange, ensuring proper alignment with bolt holes. The gasket should seat flat against the flange face without gaps or misalignment.
9. 9

   Position rear exhaust section
   Lift new rear exhaust section into position, aligning the flange with the mid-pipe connection. Support the weight with jack or jack stand while aligning. Guide exhaust hangers toward their respective mounting studs on the chassis.
10. 10

    Install flange bolts
    Insert flange bolts through the flanged connection and thread on nuts finger-tight. Apply anti-seize compound to bolt threads before installation. Do not fully tighten yet to allow for alignment adjustment.
11. 11

    Install exhaust hangers
    Working from front to rear, install each rubber exhaust hanger onto its chassis-mounted stud. Use a pry bar or exhaust hanger tool to stretch the hanger rubber over the stud. Ensure hangers are fully seated and supporting the exhaust weight evenly.
12. 12

    Align and adjust exhaust position
    With hangers installed and flange bolts finger-tight, check exhaust positioning. Ensure adequate clearance from chassis components, heat shields, fuel lines, and body panels. The exhaust should hang evenly without contact points. Make minor adjustments by loosening and repositioning as needed.
13. 13

    Torque flange bolts
    Using a torque wrench and the correct size socket, tighten the flange bolts to the factory-specified torque in a cross-pattern to ensure even compression of the flange gasket. Verify torque spec against 1992 Viper service documentation. Verify anti-seize was applied during installation.

Reassembly

1. Remove jack stands and lower vehicle to ground
2. Perform final visual inspection of all connections and clearances
3. New exhaust components may produce slight smoke or odor during first heat cycle as manufacturing oils burn off - this is normal

Verification

• Start engine and allow to idle while listening for exhaust leaks at flange connection - any hissing or ticking indicates improper seal
• Visually inspect flange connection while engine is running for signs of escaping exhaust gas
• Check that exhaust system hangs evenly without contact to chassis, body panels, or suspension components
• Perform test drive and verify no exhaust drone, rattles, or abnormal sounds
• After test drive and cool-down, re-check flange bolt torque and inspect for any signs of leakage or looseness

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