exhaust

Intermediate Pipe

for 2006 Dodge Viper 8.3L V10 · RWD

Difficulty

Moderate

Time

1.4 h

Tools

Steps

✓Fact-checked. Built from OLP's spec database, then independently fact-checked line by line with every correction applied. Master-tech sign-off by Chris Hackleman is queued. Cross-check torque values against the factory manual, and stop if anything looks unsafe. How our data is made.

Remove and replace the intermediate exhaust pipe connecting the catalytic converters to the muffler assembly on a 2005 Dodge Viper 8.3L V10.

Warnings

⚠️Allow exhaust system to cool completely before beginning work. Exhaust components can remain dangerously hot for over an hour after engine shutdown.

⚠Exhaust fasteners are prone to corrosion and seizing. Apply penetrating oil and allow soak time before attempting removal to prevent stud breakage.

⚠Support the exhaust system properly throughout the procedure to prevent component damage or personal injury from falling parts.

ℹ️Inspect all exhaust hangers and insulators during removal. Replace any that show cracking, tearing, or excessive wear.

Tools required

Floor jack and jack standsEssential

Wheel chocksEssential

13mm socket and ratchetEssential

15mm socket and ratchetEssential

18mm wrench

Torque wrench (10-50 Nm range)Essential

Penetrating oil

Anti-seize compoundEssential

Wire brush

Dead blow hammer

Pry bar

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Parts

Intermediate exhaust pipe × 1 — Use OEM specification
Exhaust flange gaskets × 2 — Use OEM specification
Exhaust hanger insulators (if worn) × 2 — Use OEM specification

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Preparation

Park vehicle on level surface and engage parking brake
Place wheel chocks behind front wheels
Allow exhaust system to cool completely (minimum 2 hours after engine shutdown)
Raise rear of vehicle using floor jack and support securely on jack stands rated for vehicle weight
Ensure adequate clearance to work under vehicle comfortably
Apply penetrating oil to all visible exhaust flange bolts and hanger fasteners, allow 15-30 minutes soak time

Procedure

1
Locate intermediate pipe assembly
Position yourself under the vehicle mid-section. Identify the intermediate pipe running from the catalytic converter/exhaust manifold flanges (forward) to the side-exit muffler inlet flanges (rearward), consistent with the Viper's side-exit dual exhaust routing. Note the two rubber hanger insulators supporting the pipe weight along its length.
2
Remove forward flange connection
Locate the forward flange connection where the intermediate pipe bolts to the catalytic converter outlets. Remove the flange bolts at this connection (verify count and socket size against the FSM; typically 2-3 bolts, commonly 13mm or 15mm). Support the intermediate pipe weight with one hand or have an assistant support it to prevent stress on the rear connection.
Torque spec
Exhaust Flange Bolts45 Nm (33 lb-ft)
3
Disconnect front exhaust hanger
Locate the front rubber exhaust hanger insulator supporting the intermediate pipe. Using a pry bar or by hand, pry the hanger loop off the hanger bracket. Work the rubber insulator off the pipe hook by rotating and pulling. If the insulator is severely deteriorated, it may need to be cut off.
4
Remove rear flange connection
Locate the rear flange connection where the intermediate pipe bolts to the muffler inlet. Remove the flange bolts at this connection (verify count and socket size against the FSM; typically 2-3 bolts, commonly 13mm or 15mm). The intermediate pipe is now free at both ends.
Torque spec
Exhaust Flange Bolts45 Nm (33 lb-ft)
5
Disconnect rear exhaust hanger
Locate the rear rubber exhaust hanger insulator supporting the intermediate pipe. Pry or pull the hanger loop off the bracket to fully release the intermediate pipe from the vehicle. Carefully lower the pipe and remove it from under the vehicle.
6
Clean flange surfaces
Using a wire brush, thoroughly clean the flange mating surfaces on both the catalytic converter outlets and muffler inlets. Remove all old gasket material, carbon deposits, and corrosion. Inspect flanges for warping or damage. Clean the threads on all flange studs or bolt holes.
7
Inspect and prepare hangers
Inspect both rubber exhaust hanger insulators removed from the intermediate pipe. Check for cracks, tears, or excessive wear. Replace if damaged. Inspect the hanger brackets on the vehicle for cracks or damage. If reusing insulators, apply a light coating of soapy water or silicone spray to ease installation.
8
Install new flange gaskets
Position new exhaust flange gaskets onto the catalytic converter outlet flanges and muffler inlet flanges. Ensure gaskets are properly aligned with bolt holes and sealing surfaces. The gaskets should sit flat against the flange faces.
9
Position new intermediate pipe
Lift the new intermediate pipe into position under the vehicle. Align the forward flange with the catalytic converter outlets and the rear flange with the muffler inlets. Thread the forward flange bolts by hand to hold the pipe in position, but do not tighten yet.
10
Install exhaust hangers
Connect the front rubber hanger insulator to its bracket by working the hanger loop onto the hook. Repeat for the rear hanger insulator. The pipe should now be supported by both hangers. Adjust pipe position as needed to ensure proper alignment at both flanges.
11
Install rear flange bolts
Thread the rear flange bolts by hand at the muffler connection. Apply a small amount of anti-seize compound to the bolt threads. Tighten the bolts in a cross pattern to the manufacturer-specified torque (verify exact value in the FSM) using a torque wrench.
Torque spec
Exhaust Flange Bolts45 Nm (33 lb-ft)
12
Torque forward flange bolts
Apply anti-seize compound to the forward flange bolt threads. Tighten the forward flange bolts in a cross pattern to the manufacturer-specified torque (verify exact value in the FSM) using a torque wrench. Verify that all flange connections are secure and gaskets are properly seated.
Torque spec
Exhaust Flange Bolts45 Nm (33 lb-ft)
13
Verify installation clearances
Visually inspect the installed intermediate pipe for proper clearance from the vehicle underbody, chassis components, driveshaft, and fuel lines. There should be no contact points. Check that rubber hangers are not overstretched or misaligned. Adjust pipe position if necessary by loosening flange bolts slightly and repositioning.

Reassembly

Installation is performed in steps 8-13 above
Ensure all flange bolts are torqued to specification with anti-seize applied
Verify exhaust hangers are properly seated and not overstretched
Confirm no contact between exhaust components and vehicle body or chassis

Verification

Lower vehicle from jack stands and remove wheel chocks
Start engine and listen for exhaust leaks at both flange connections (listen for ticking or hissing sounds)
Allow engine to reach operating temperature and recheck for leaks
Perform test drive and verify no exhaust drone, rattling, or abnormal vibrations
After test drive, raise vehicle and perform final visual inspection of all connections and clearances while exhaust is hot
Check flange bolt torque after first heat cycle if possible