Exhaust Tip

This procedure covers removal and installation of the exhaust tip on a 2005 Dodge Viper 8.3L V10, typically for replacement or cosmetic upgrade.

Warnings

Tools required

Parts

• Exhaust tip × 1 — Mopar 05047797AA (OEM) or aftermarket equivalent
• Exhaust tip clamp bolt and nut (if corroded) × 1 — M8x30mm stainless hardware

Preparation

1. Ensure exhaust system is completely cool to the touch (minimum 2 hours after last operation)
2. Park vehicle on level surface and engage parking brake
3. Place wheel chocks at front wheels
4. Raise rear of vehicle with floor jack and support securely on jack stands rated for vehicle weight (approximately 3,300 lbs)
5. Verify jack stands are positioned on frame rails, not on suspension components or exhaust

Procedure

1. 1

   Access exhaust tip clamp
   Position yourself under the rear of the vehicle with adequate lighting. Locate the exhaust tip at the rear exit of the muffler assembly. The tip is secured by a band clamp with a single bolt and nut accessible from below. Inspect the clamp hardware for corrosion.
2. 2

   Apply penetrating oil (if needed)
   If clamp hardware shows corrosion or surface rust, spray penetrating oil on the bolt threads and clamp joint. Allow 10-15 minutes soak time before proceeding. This step is critical for preventing bolt breakage on corroded fasteners.
3. 3

   Loosen exhaust tip clamp
   Using the correct socket for the clamp bolt head (verify size on the actual hardware) with an extension, loosen the clamp bolt securing the exhaust tip. The nut is typically welded to the clamp bracket, so rotate the bolt counterclockwise. Loosen completely but do not remove the bolt yet.
4. 4

   Remove clamp bolt and separate clamp
   Remove the clamp bolt completely. Open the band clamp by prying the clamp ends apart slightly. The clamp should separate enough to allow tip removal. If the clamp remains tight on the pipe, tap the clamp tabs gently with a small hammer to break the grip.
5. 5

   Remove exhaust tip
   Slide the exhaust tip rearward off the muffler outlet pipe. The tip may require twisting motion if carbon buildup has created resistance. Do not force; apply additional penetrating oil and allow soak time if tip does not move freely. Once free, pull tip completely away from vehicle.
6. 6

   Clean muffler outlet pipe
   Use wire brush to remove carbon deposits and corrosion from the muffler outlet pipe where the new tip will seat. Clean surface ensures proper clamp grip and prevents exhaust leaks. Wipe clean with shop towel.
7. 7

   Install new exhaust tip
   Slide the new exhaust tip onto the muffler outlet pipe. Orient the tip so it aligns properly with the side-exit outlet opening, matching the original tip angle relative to the rocker/sill panel. Insert tip approximately 2-3 inches onto the outlet pipe for proper overlap.
8. 8

   Position and tighten clamp
   Position the band clamp over the joint between the muffler outlet pipe and exhaust tip. Ensure clamp is centered on the overlap area. Insert clamp bolt and hand-tighten. Before final tightening, verify tip alignment with fascia cutout and adjust as necessary. Tighten clamp bolt to the clamp manufacturer's specified torque (typically around 15-18 lb-ft for M8 hardware; verify spec). Snug but do not overtighten, as excessive torque can deform the tip.

Reassembly

1. No disassembly was required beyond the exhaust tip removal itself
2. Ensure exhaust tip is aligned concentrically within rear fascia cutout with approximately equal clearance on all sides
3. Verify clamp is fully tightened and tip does not rotate on pipe when hand pressure is applied

Verification

• Start engine and allow to idle. Listen for exhaust leaks at the tip-to-muffler joint (hissing or ticking sounds indicate loose clamp)
• Visually inspect tip alignment from rear of vehicle while running; tip should remain stable without vibration or movement
• Check tip-to-fascia clearance after thermal expansion by running engine to operating temperature, then shutting off and immediately inspecting clearance (tip will expand slightly when hot)

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