Muffler

Removal and replacement of the rear muffler assembly on a 1992 Dodge Viper, including disconnection from exhaust pipes and removal of rubber hangers.

Warnings

Tools required

Parts

• Muffler assembly × 1 — Use OEM specification or performance equivalent
• Exhaust clamps × 2 — Use OEM specification
• Rubber exhaust hangers × 2 — Replace if cracked or deteriorated

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Place wheel chocks behind rear wheels.
3. Allow exhaust system to cool completely if vehicle was recently operated.
4. Apply penetrating oil to all exhaust clamp bolts and allow to soak for 15-30 minutes.
5. Raise vehicle using floor jack at manufacturer-specified lift points and secure on jack stands at appropriate height to access exhaust system.
6. Verify vehicle is stable on jack stands before working underneath.

Procedure

1. 1

   Locate muffler assembly
   Position yourself under the vehicle on the driver's side. The muffler assembly is located behind the door sill area, between the catalytic converters and the side-exit exhaust outlets. Identify the forward inlet connection, rear outlet connection, and the rubber hanger mounting points.
2. 2

   Disconnect forward exhaust connection
   Locate the exhaust clamp connecting the muffler inlet to the intermediate pipe from the catalytic converters. Using a 15mm socket, remove the 2 bolts securing the exhaust clamp. Separate the joint by gently twisting and pulling the muffler rearward. If the connection is seized, tap gently with a rubber mallet while applying twisting motion.
   Torque spec

   Muffler Clamps55 Nm (41 lb-ft)
3. 3

   Disconnect rear exhaust connection
   Locate the exhaust clamp connecting the muffler outlet to the tailpipe section. Using a 15mm socket, remove the 2 bolts securing the exhaust clamp. Separate the joint by gently twisting and pulling the sections apart. The tailpipe will remain attached to the vehicle.
   Torque spec

   Muffler Clamps55 Nm (41 lb-ft)
4. 4

   Identify rubber hanger locations
   Locate the 2 rubber exhaust hangers supporting the muffler assembly. One hanger is typically positioned near the forward portion of the muffler, the other near the rear. Each hanger consists of a metal rod welded to the muffler that inserts into a rubber isolator mounted to the chassis.
5. 5

   Support muffler assembly
   Have an assistant support the muffler assembly from below, or use a floor jack with a block of wood to support the weight. The muffler will become free once the hangers are disconnected.
6. 6

   Remove forward hanger
   Using a pry bar or by hand, push the muffler assembly toward the rubber isolator to create slack, then pull the metal hanger rod out of the rubber isolator. Apply penetrating oil if the connection is seized. Twist and pull the rod free from the rubber mount.
7. 7

   Remove rear hanger
   Repeat the hanger removal process for the rear rubber isolator. Push the muffler to create slack, then pull the metal hanger rod free from the rubber mount. The muffler assembly is now free from the vehicle.
8. 8

   Remove muffler assembly
   Carefully lower the muffler assembly and remove it from under the vehicle. Maneuver it out from the side, taking care not to damage brake lines, fuel lines, or body panels. The assembly may be heavy and awkward to handle.
9. 9

   Inspect mounting points and components
   Inspect the rubber hanger isolators for cracking, tearing, or deterioration. Replace any damaged isolators. Clean the exhaust pipe connection points with a wire brush to remove carbon deposits and corrosion. Inspect the intermediate pipe and tailpipe for damage or excessive corrosion.
10. 10

    Prepare new muffler
    Position the new muffler assembly near the installation area. Verify that all mounting rods and connection flanges are present and undamaged. Apply a small amount of penetrating oil or anti-seize to the hanger rods to ease installation into rubber isolators.
11. 11

    Install muffler assembly into position
    Lift the new muffler assembly into position under the vehicle. Align the inlet and outlet pipes with their respective connections. Support the muffler with a floor jack or have an assistant hold it in position.
12. 12

    Install forward hanger
    Insert the forward metal hanger rod into its rubber isolator. Push or pull the muffler as needed to align the rod with the isolator opening. Use a pry bar if necessary to lever the rod into the rubber mount. Ensure the rod is fully seated in the isolator.
13. 13

    Install rear hanger
    Insert the rear metal hanger rod into its rubber isolator. Manipulate the muffler position to align the rod with the isolator opening and push it fully into place. Verify both hangers are fully engaged and supporting the muffler weight.
14. 14

    Connect forward exhaust joint
    Align the muffler inlet pipe with the intermediate pipe from the catalytic converters. The pipes should overlap with the connection flange positioned at the joint. Install a new exhaust clamp over the joint. Hand-thread the 2 clamp bolts using a 15mm socket. Do not fully tighten at this stage.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
15. 15

    Connect rear exhaust joint
    Align the muffler outlet pipe with the tailpipe section. Install a new exhaust clamp over the joint. Hand-thread the 2 clamp bolts using a 15mm socket. Do not fully tighten at this stage.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
16. 16

    Align exhaust system
    With all connections loosely assembled, adjust the position of the muffler assembly to ensure proper alignment and adequate clearance from the chassis, body panels, brake lines, and fuel lines. Verify minimum 1-inch clearance from all components. Check that the side-exit tailpipe is properly positioned relative to the body.
17. 17

    Torque exhaust clamps
    Once alignment is verified, tighten the forward exhaust clamp bolts to 55.0 Nm (41 lb-ft) using a torque wrench and 15mm socket. Tighten the rear exhaust clamp bolts to the same specification. Tighten clamp bolts in a cross pattern to ensure even clamping pressure.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
18. 18

    Final inspection
    Visually inspect all connections to verify clamps are properly seated and torqued. Verify rubber hangers are fully engaged and supporting the muffler. Check exhaust system clearances throughout the full length to ensure no contact points with chassis or body components.

Reassembly

1. Lower vehicle from jack stands using floor jack.
2. Remove jack stands and lower vehicle completely to ground.
3. Remove wheel chocks.

Verification

• Start engine and allow to idle. Listen for exhaust leaks at both clamp connections. A leak will produce a loud hissing or ticking sound.
• With engine running, visually inspect clamp areas for escaping exhaust gases.
• Rev engine moderately and verify no abnormal exhaust sounds or rattles.
• Perform a test drive and monitor for exhaust drone, vibration, or any contact between exhaust components and chassis.
• After test drive, re-inspect all connections and clearances while exhaust is warm but safe to approach.
• Re-check torque on exhaust clamp bolts after initial heat cycle if desired.

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