Tail Pipe

Remove and replace the tail pipe section of the exhaust system on a 1992 Dodge Viper, including disconnection from muffler/exhaust components and rubber hangers.

Warnings

Tools required

Parts

• Tail pipe assembly × 1 — Use OEM specification or equivalent aftermarket
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust hanger rubber isolators × 2 — Replace if cracked or damaged

Preparation

1. Ensure exhaust system is completely cool to the touch
2. Park vehicle on level surface and apply parking brake
3. Place wheel chocks behind front wheels
4. Raise rear of vehicle with floor jack and support securely on jack stands at approved lift points
5. Spray all exhaust flange bolts and hanger bolt areas with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Inspect exhaust routing and support points
   From beneath the vehicle, locate the tail pipe/side-exit exhaust section running from the muffler outlet to the side sill exit ahead of the rear wheel. Identify the flange connection point where the tail pipe connects to the muffler or intermediate pipe, and note the rubber hanger locations supporting the tail pipe. Note the rubber hanger isolators supporting the tail pipe/side-exit section; verify the exact count against OEM documentation for this vehicle.
2. 2

   Support the tail pipe
   Position a floor jack or support stand under the tail pipe near its midpoint to prevent it from dropping when fasteners are removed. Adjust height so the pipe is slightly supported but not under tension.
3. 3

   Remove flange connection bolts
   Locate the flange connection between the tail pipe and the upstream exhaust component (muffler or intermediate pipe). Using the appropriate socket and ratchet, remove the flange bolts securing the connection; verify the exact bolt count and size against OEM documentation. Work the bolts back and forth if they are seized, applying additional penetrating oil as needed. Keep the old flange gasket for reference.
   Torque spec

   Exhaust Flange Bolts31 Nm (23 lb-ft)
4. 4

   Disconnect tail pipe from flange
   Once bolts are removed, separate the tail pipe flange from the mating flange. The pipe may be stuck due to carbon buildup. Gently twist and pull to break the seal. Remove and discard the old flange gasket.
5. 5

   Remove tail pipe from rear hanger
   Locate the rearmost rubber hanger isolator near the tail pipe exit. Using a pry bar or by hand, work the tail pipe hanger rod out of the rubber isolator by pushing the pipe toward the front of the vehicle and lifting the rod out of the rubber grommet. This may require significant force if the rubber is not deteriorated.
6. 6

   Remove tail pipe from forward hanger
   Locate the forward rubber hanger isolator supporting the tail pipe. Using the same technique, work the tail pipe hanger rod out of the rubber isolator. With both hangers disconnected, the tail pipe should be free to remove.
7. 7

   Remove tail pipe from vehicle
   Lower the support jack slightly and maneuver the tail pipe assembly out from under the vehicle. It will exit toward the side of the vehicle at the sill area ahead of the rear wheel. Be aware of sharp edges on the cut end of the pipe.
8. 8

   Inspect and clean mounting points
   Inspect the rubber hanger isolators still mounted to the vehicle frame. Replace any that are cracked, torn, or severely deteriorated. Clean the mating flange surface on the upstream exhaust component with a wire brush to remove carbon buildup and old gasket material, creating a clean, flat sealing surface.
9. 9

   Prepare new tail pipe
   Unpack the new tail pipe assembly and verify it matches the original in length, diameter, and hanger rod positions. Apply a thin coat of anti-seize compound to the threads of the new flange bolts (or cleaned original bolts if reusing).
10. 10

    Install new tail pipe into hangers
    Maneuver the new tail pipe assembly into position under the vehicle from the rear. Support it with a jack or stand. Starting with the forward hanger, insert the hanger rod into the rubber isolator. You may need to use a pry bar to spread the rubber opening. Repeat for the rear hanger, ensuring the pipe is properly seated in both isolators.
11. 11

    Install new flange gasket and connect pipe
    Position the new flange gasket over the studs or bolt holes on the upstream exhaust component flange. Align the tail pipe flange with the mating flange, ensuring the gasket remains properly positioned between them.
12. 12

    Install and torque flange bolts
    Insert the 2 flange bolts (with anti-seize already applied) through the flange connection. Thread them by hand to ensure proper engagement. Using the appropriate socket and torque wrench, tighten the bolts in a cross pattern to the OEM-specified torque value for this vehicle's exhaust flange fasteners. This ensures even gasket compression and prevents leaks.
    Torque spec

    Exhaust Flange Bolts31 Nm (23 lb-ft)
13. 13

    Verify tail pipe alignment and clearance
    Check that the tail pipe exits cleanly through the side sill opening without contact. Verify adequate clearance between the tail pipe and any chassis components, fuel lines, or body panels. There should be at least 25mm (1 inch) clearance to all components. Adjust by repositioning the pipe in the rubber hangers if necessary.
14. 14

    Remove support and lower vehicle
    Remove the jack or support stand from under the tail pipe. Lower the vehicle from the jack stands and remove stands. Lower the vehicle completely to the ground.

Reassembly

1. No additional reassembly required beyond the installation steps above

Verification

• Start the engine and allow it to idle. Listen for exhaust leaks at the flange connection. Any hissing or excessive noise indicates a leak that must be corrected.
• With the engine running, carefully feel around the flange connection for escaping exhaust gases (keep hands at safe distance from hot surfaces).
• Visually inspect the tail pipe position to ensure it remains properly aligned in the hangers and exits the bumper cleanly without rubbing.
• After a short test drive, re-check the flange bolts for tightness and verify no exhaust odors are entering the cabin.

More procedures for this vehicle