Intermediate Pipe

Remove and replace the intermediate exhaust pipe section on a 1992 Dodge Viper, including disconnection from catalytic converters and muffler assembly.

Warnings

Tools required

Parts

• Intermediate exhaust pipe × 1 — Use OEM specification or equivalent
• Exhaust flange gaskets (catalytic converter to intermediate pipe) × 2 — Use OEM specification
• Exhaust flange gasket (intermediate pipe to muffler) × 1 — Use OEM specification
• Exhaust hanger bushings (if deteriorated) × 2 — Inspect during removal

Preparation

1. Ensure engine and exhaust system are completely cold to the touch
2. Park vehicle on level, solid ground and engage parking brake
3. Place wheel chocks behind rear wheels
4. Raise front of vehicle using floor jack at designated lift points and support on jack stands rated for vehicle weight
5. Visually inspect exhaust system for existing damage or modifications that may affect procedure
6. Apply penetrating oil liberally to all visible exhaust flange bolts and allow to soak for at least 15 minutes before beginning removal

Procedure

1. 1

   Access intermediate pipe from under vehicle
   Position yourself under the vehicle with adequate lighting. The intermediate pipe runs from the exhaust manifold/downpipe outlets (one per cylinder bank) to the inlet of the muffler assembly. Note: the 1992 Viper R/T-10 was not factory-equipped with catalytic converters, so verify actual routing on the specific vehicle. Identify the front flanged connections at each catalytic converter outlet and the rear flanged connection at the muffler inlet. Locate the rubber exhaust hangers supporting the intermediate pipe section.
2. 2

   Disconnect forward flange connections at catalytic converters
   Starting with the driver-side connection, remove the flange bolts connecting the intermediate pipe to the upstream (manifold/downpipe) outlet using the correct socket. Support the pipe as you remove the final bolt to prevent it from dropping. Repeat for the passenger-side connection. Verify exact bolt count and size against the factory service manual before beginning. Allow the forward end of the intermediate pipe to hang supported by the rear connection and hangers.
   Torque spec

   Exhaust Flange Bolts33 Nm (24 lb-ft)
3. 3

   Support intermediate pipe section
   Position a jack stand or secure support under the intermediate pipe section near its center point to prevent stress on the remaining connection. The pipe assembly is heavy and awkward; adequate support prevents damage to the muffler flange and hanger bushings.
4. 4

   Remove rear flange connection at muffler inlet
   Remove the flange bolts connecting the rear of the intermediate pipe to the muffler inlet using the correct socket. Verify exact bolt count and size against the factory service manual before beginning. These bolts are often more corroded due to moisture accumulation. If bolts are severely corroded and resistant, apply additional penetrating oil and allow to soak, or carefully apply heat if safe to do so.
   Torque spec

   Exhaust Flange Bolts33 Nm (24 lb-ft)
5. 5

   Disconnect exhaust hangers
   Identify the rubber exhaust hangers supporting the intermediate pipe section (verify exact count on the specific vehicle). Using a pry bar or by hand, work the metal hanger loops out of the rubber bushings. The rubber bushings may be stiff; lubricate with soapy water if needed to ease removal. Inspect rubber bushings for cracking or deterioration and replace if damaged.
   ⚠The intermediate pipe will become free once hangers are disconnected. Ensure adequate support is in place before removing final hanger.
6. 6

   Remove intermediate pipe assembly
   With all connections and hangers disconnected, carefully lower and maneuver the intermediate pipe assembly out from under the vehicle. The pipe routing may require rotation or angling to clear suspension components and the driveshaft. Remove old flange gaskets from all three connection points and discard.
7. 7

   Clean flange surfaces
   Using a wire brush, thoroughly clean the mating flange surfaces on both catalytic converter outlets and the muffler inlet. Remove all old gasket material, carbon buildup, and corrosion to ensure proper sealing of new gaskets. Inspect flange faces for warping or damage that could cause exhaust leaks.
8. 8

   Prepare new intermediate pipe
   Inspect the new intermediate pipe for shipping damage and verify correct fitment. Place new exhaust flange gaskets on the forward connections (catalytic converter outlets) and the rear connection (muffler inlet). Apply a thin coat of anti-seize compound to the threads of all flange bolts.
9. 9

   Position and support new intermediate pipe
   Maneuver the new intermediate pipe into position under the vehicle, routing it through the same path as the original. Align the forward flanges with the catalytic converter outlets and the rear flange with the muffler inlet. Use a jack stand or support to hold the pipe at approximately the correct height and angle for connection.
10. 10

    Install exhaust hangers
    Connect the 2 rubber exhaust hangers by inserting the metal hanger loops on the intermediate pipe into the rubber bushings. This may require manipulation of pipe position; use a pry bar carefully if needed. Ensure hangers are fully seated and supporting the pipe weight.
    ℹ️Installing hangers before tightening flange bolts allows the pipe to hang naturally and reduces stress on flange connections.
11. 11

    Install forward flange bolts at catalytic converters
    Starting with the driver-side connection, install the 3 flange bolts finger-tight, ensuring the gasket remains properly positioned. Repeat for the passenger-side connection. Verify both flanges are aligned properly and gaskets are not pinched or displaced. Do not fully torque at this stage.
    Torque spec

    Exhaust Flange Bolts33 Nm (24 lb-ft)
12. 12

    Install rear flange bolts at muffler inlet
    Install the 3 flange bolts at the muffler connection finger-tight, ensuring the gasket is properly seated. Check overall alignment of the entire intermediate pipe section. The pipe should hang naturally without binding or stress at any connection point. Adjust hanger positions slightly if needed to achieve proper alignment.
    Torque spec

    Exhaust Flange Bolts33 Nm (24 lb-ft)
13. 13

    Torque all flange connections
    Using a torque wrench, tighten all flange bolts to the factory-specified torque (verify exact value in the Viper service manual; typical M8 exhaust flange fasteners are ~17 ft-lbs / 23 Nm) in a star pattern at each connection to ensure even gasket compression. Torque the driver-side catalytic converter flange bolts first, then passenger-side, then the rear muffler flange bolts. After all bolts are torqued, perform a second pass to verify torque values as gaskets may compress slightly during initial tightening.
    Torque spec

    Exhaust Flange Bolts33 Nm (24 lb-ft)

Reassembly

1. Verify all flange bolts are torqued to specification and no fasteners were missed
2. Ensure exhaust hangers are fully seated in their rubber bushings
3. Check for adequate clearance between intermediate pipe and all surrounding components (driveshaft, suspension, frame rails)
4. Lower vehicle from jack stands safely

Verification

• Start engine and allow to idle; listen for exhaust leaks at all three flange connections
• With engine at idle, visually inspect all flange connections for escaping exhaust gases
• Rev engine to 2000-3000 RPM and verify no exhaust leaks develop under increased flow
• After test drive and engine cool-down, re-check torque on all flange bolts as gaskets may settle during initial heat cycles
• Verify intermediate pipe does not contact any surrounding components during suspension articulation or engine movement

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