Exhaust Gasket - Front

Replace the front exhaust manifold gaskets on a 2005 Dodge Viper 8.3L V10, requiring removal of exhaust manifold heat shields and manifolds to access and replace the gaskets.

Warnings

Tools required

Parts

• Exhaust manifold gasket set (both banks) × 1 — Use OEM Mopar specification
• Exhaust flange gaskets × 2 — Use OEM specification

Preparation

1. Ensure the engine has been off for at least 4 hours and is completely cool to the touch
2. Disconnect the negative battery terminal to prevent accidental electrical shorts
3. Raise the vehicle on a lift or securely support on jack stands to access underside components
4. Apply penetrating oil to all visible exhaust manifold bolts, heat shield fasteners, and oxygen sensor threads
5. Allow the vehicle to sit for 30-60 minutes after applying penetrating oil for better fastener release

Procedure

1. 1

   Remove oxygen sensors
   Locate the oxygen sensors on both exhaust manifolds. Disconnect the electrical connectors by releasing the locking tabs. Using an O2 sensor socket or 22mm wrench, carefully unthread each oxygen sensor from the exhaust manifold. Work slowly to avoid breaking the sensors if you plan to reuse them. Set sensors aside in a clean area.
2. 2

   Remove exhaust manifold heat shields
   Locate the heat shield bolts securing the heat shields to each exhaust manifold. The Viper V10 has heat shields covering both banks. Remove all heat shield mounting bolts and carefully lift the heat shields away from the manifolds. The shields may be stuck due to heat cycling; gently work them free if needed.
3. 3

   Disconnect exhaust downpipes from manifolds
   Working from underneath the vehicle, locate the exhaust flange connections where the downpipes meet the exhaust manifolds. Remove the flange bolts connecting each downpipe to its respective manifold (typically 2 bolts per side). Support the downpipe weight to prevent stress on the exhaust system. Separate the flanges and remove the old flange gaskets.
4. 4

   Remove exhaust manifold fasteners - driver side
   Beginning with the driver side (left bank), systematically remove all exhaust manifold mounting bolts or nuts. The Viper V10 secures each manifold to the cylinder head with bolts (verify exact count and type against the FSM). Note the location of each fastener for reinstallation. Use a combination of extensions and universal joints to access fasteners in tight areas near the firewall and shock towers. Keep fasteners organized by location for reinstallation.
5. 5

   Remove driver side exhaust manifold
   With all fasteners removed, carefully work the driver side exhaust manifold away from the cylinder head. The manifold may be stuck to the old gasket. Gently rock and pull the manifold to break the gasket seal. Lift the manifold out of the engine bay, being careful not to damage surrounding components. Remove and discard the old exhaust gasket from the cylinder head mounting surface.
6. 6

   Remove exhaust manifold fasteners - passenger side
   Repeat the fastener removal process for the passenger side (right bank) exhaust manifold. Remove all manifold mounting fasteners (verify exact count against the FSM), using extensions and universal joints as needed. Access may be slightly different on this side due to steering and other components. Work methodically to ensure all fasteners are removed.
7. 7

   Remove passenger side exhaust manifold
   Carefully remove the passenger side exhaust manifold from the cylinder head. Work it free from the old gasket and lift it clear of the engine compartment. Remove and discard the old exhaust gasket from the cylinder head mounting surface.
8. 8

   Clean mating surfaces
   Using a plastic or brass gasket scraper, thoroughly clean all old gasket material from both cylinder head exhaust ports. Clean all 10 exhaust port surfaces (5 per bank) completely. Use a wire brush to clean the manifold mating surfaces as well. Ensure no carbon deposits, old gasket material, or debris remain. Wipe surfaces clean with a lint-free cloth. Inspect the cylinder head surfaces for warping or damage; minor surface imperfections are acceptable, but deep gouges or cracks require cylinder head service.
9. 9

   Install new gaskets and passenger side manifold
   Position a new exhaust manifold gasket onto the passenger side cylinder head, aligning all port openings. The gasket should fit snugly against the head surface. Carefully position the passenger side exhaust manifold over the studs, aligning it with the gasket. Start all mounting fasteners by hand onto the studs, threading them several turns to ensure proper engagement. Do not tighten at this stage.
10. 10

    Torque passenger side manifold fasteners
    If OEM procedure permits, apply a small amount of high-temperature anti-seize to the stud threads and adjust torque accordingly (avoid getting anti-seize on the gasket mating surface). Torque the exhaust manifold nuts in a center-outward pattern, working from the middle cylinders toward the ends. Tighten in stages to the OEM-specified final torque (verify exact value and staged sequence against the FSM for the 2005 Viper 8.3L V10). This staged approach ensures even gasket compression and prevents warping.
    Torque spec

    Exhaust Flange Bolt45 Nm (33 lb-ft)
11. 11

    Install new gaskets and driver side manifold
    Position a new exhaust manifold gasket onto the driver side cylinder head, aligning all port openings. Carefully position the driver side exhaust manifold over the studs and align with the gasket. Start all mounting fasteners by hand, threading them several turns before proceeding.
12. 12

    Torque driver side manifold fasteners
    Apply anti-seize compound to the exposed stud threads. Torque the exhaust manifold nuts using the same center-outward pattern and staged process to the OEM-specified final torque (verify exact values against the FSM for the 2005 Viper 8.3L V10).
    Torque spec

    Exhaust Flange Bolt45 Nm (33 lb-ft)
13. 13

    Reconnect exhaust downpipes
    Install new exhaust flange gaskets at the connection points between the exhaust manifolds and downpipes. Align the downpipes with the manifold outlets and start the flange bolts by hand. Apply anti-seize compound to the flange bolt threads. Torque the flange bolts to the OEM-specified value on both sides (verify against the FSM for the 2005 Viper 8.3L V10).
14. 14

    Reinstall heat shields
    Position the heat shields over each exhaust manifold, aligning the mounting holes. Install all heat shield mounting bolts and torque to 10 Nm (7 lb-ft). Ensure the shields are properly seated and not touching or interfering with any other components.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
15. 15

    Reinstall oxygen sensors
    Apply a thin coat of anti-seize compound to the threads of each oxygen sensor (avoid getting anti-seize on the sensor tip). Thread each sensor into its respective exhaust manifold port by hand to prevent cross-threading. Torque the oxygen sensors to the OEM-specified value (typically around 30 Nm / 22 lb-ft; verify against the FSM). Reconnect the electrical connectors to each sensor, ensuring the locking tabs engage fully.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)

Reassembly

1. Reconnect the negative battery terminal
2. Lower the vehicle from the jack stands or lift
3. Before starting the engine, visually inspect all exhaust connections to ensure proper assembly

Verification

• Start the engine and allow it to idle. Listen carefully for any exhaust leaks around the manifold gaskets, flange connections, and oxygen sensor ports
• With the engine running, carefully inspect (without touching) all exhaust connections for visible exhaust gas escaping
• Allow the engine to reach operating temperature and recheck all connection points for leaks
• Test drive the vehicle and verify no exhaust smell enters the cabin and no unusual exhaust noise is present
• After the first heat cycle, consider rechecking manifold nut torque when the engine is cool (optional but recommended for critical applications)

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