Muffler

Remove and replace the muffler assembly on a 2005 Dodge Viper, including disconnection from the exhaust system and mounting hangers.

Warnings

Tools required

Parts

• Muffler assembly × 1 — Use OEM specification or direct replacement
• Exhaust clamp (if reusing is not possible) × 2 — Use OEM specification
• Rubber exhaust hangers (if damaged) × 2 — Use OEM specification

Preparation

1. Ensure engine and exhaust system are completely cold to the touch
2. Park vehicle on level, solid surface and engage parking brake
3. Place wheel chocks at front wheels
4. Apply penetrating oil to all visible exhaust clamps and hanger bracket bolts, allow to soak for 15-20 minutes

Procedure

1. 1

   Raise and support vehicle
   Raise the rear of the vehicle using a floor jack at the rear differential housing or factory lift point. Support the vehicle securely on jack stands placed under the rear subframe or designated lift points. Verify the vehicle is stable before working underneath. The muffler/resonator assembly on this side-exit exhaust system is accessible from underneath along the vehicle's side, ahead of the rear wheel; verify exact location on the actual vehicle.
2. 2

   Inspect exhaust system routing
   From underneath the vehicle, locate the muffler assembly. Identify the inlet connection from the mid-pipe assembly (ahead of the muffler), the outlet connection to the rear tailpipes, and the rubber exhaust hangers supporting the muffler. Note the number and location of rubber hangers supporting the muffler assembly, as the 2005 Viper uses side-exit exhaust routing; verify hanger count and positions against the actual vehicle before proceeding. Note the orientation of clamps and hanger positions for reinstallation.
3. 3

   Loosen inlet exhaust clamp
   Locate the exhaust clamp connecting the muffler inlet to the mid-pipe. Using the correct socket for the clamp fastener (verify size on the actual vehicle), loosen the clamp bolt until the clamp can slide freely. Do not fully remove the bolt at this time. If the clamp is seized, apply additional penetrating oil and use a wire brush to clean threads. Inspect clamp for damage or excessive corrosion; replace if necessary.
4. 4

   Loosen outlet exhaust clamp
   Locate the exhaust clamp connecting the muffler outlet to the rear tailpipe assembly. Using a 15mm socket, loosen the clamp bolt until the clamp can slide freely. Do not fully remove the bolt at this time. This clamp may be more accessible from the side of the vehicle depending on the exact tailpipe routing.
5. 5

   Remove forward rubber exhaust hanger
   Locate the forward rubber hanger supporting the muffler. Using an exhaust hanger removal tool or large flathead screwdriver, pry the rubber hanger off its mounting bracket on the muffler. Apply leverage carefully to stretch the rubber and slide it off the hook. Inspect the rubber hanger for cracks or deterioration; replace if damaged.
6. 6

   Remove rear rubber exhaust hanger
   Locate the rear rubber hanger supporting the muffler. Using an exhaust hanger removal tool or large flathead screwdriver, pry the rubber hanger off its mounting bracket on the muffler. The muffler will now be supported only by the inlet and outlet pipe connections. Have an assistant or suitable support ready to prevent the muffler from dropping.
7. 7

   Support and disconnect muffler
   Position a floor jack or have an assistant support the weight of the muffler. Slide the inlet clamp forward on the mid-pipe and the outlet clamp rearward on the tailpipe to clear the muffler connections. Carefully separate the muffler from the inlet pipe by twisting and pulling rearward. Then separate the outlet connection from the tailpipe by twisting and pulling the tailpipe rearward. Lower the muffler carefully and remove it from underneath the vehicle. The pipes may require gentle rocking or rotation to break the seal from soot buildup.
8. 8

   Inspect and clean connections
   Inspect the inlet pipe from the mid-pipe and the outlet connection point on the tailpipe for damage, excessive corrosion, or deformation. Use a wire brush to clean the outer diameter of both pipe ends to ensure proper sealing with the new muffler. Check that the rubber hangers on the chassis mounting points are in good condition and securely attached. Replace any damaged components before installing the new muffler.
9. 9

   Position new muffler
   With an assistant or jack supporting the new muffler, position it underneath the vehicle aligned with the inlet and outlet pipe connections. Slide the muffler inlet over the mid-pipe connection and the muffler outlet into the tailpipe connection. Do not fully seat the pipes yet; leave approximately 1 inch of clearance for alignment adjustments. Verify the muffler is oriented correctly with inlet facing forward.
10. 10

    Install exhaust hangers
    Install the forward rubber exhaust hanger by stretching the rubber loop over the muffler mounting bracket hook. Use a pry bar or screwdriver to assist in stretching the rubber if necessary. Repeat for the rear rubber hanger. The hangers will hold the muffler in approximate position while you finalize pipe connections and clamps.
11. 11

    Adjust alignment and seat pipes
    With the muffler supported by the hangers, adjust the position to ensure equal insertion depth at both inlet and outlet connections (typically 1.5-2 inches overlap). Ensure the muffler hangs correctly and does not contact the chassis, rocker panel, side sill, or body structure. Push the inlet and outlet pipes fully together to seat them properly.
12. 12

    Install and torque inlet clamp
    Slide the inlet exhaust clamp into position over the joint between the mid-pipe and muffler inlet. Center the clamp over the joint. Using a torque wrench and the correct socket, torque the clamp bolt to the manufacturer-specified value (verify against factory service documentation). Ensure the clamp is positioned correctly and tightens evenly.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
13. 13

    Install and torque outlet clamp
    Slide the outlet exhaust clamp into position over the joint between the muffler outlet and tailpipe. Center the clamp over the joint. Using a torque wrench and the correct socket, torque the clamp bolt to the manufacturer-specified value (verify against factory service documentation). Ensure the clamp is positioned correctly and tightens evenly.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
14. 14

    Final clearance inspection
    Verify the muffler has adequate clearance (minimum 1 inch) from all surrounding components including chassis, fuel tank, rear axle, and suspension components. Check that all rubber hangers are properly seated and supporting the muffler evenly. Gently push and pull on the muffler to confirm it is securely mounted and does not have excessive movement.
15. 15

    Lower vehicle and test
    Carefully lower the vehicle from the jack stands and remove all support equipment. Start the engine and inspect all connections for exhaust leaks while the engine is idling. Listen for any hissing or abnormal exhaust sounds at the clamp locations. Rev the engine slightly and recheck. If any leaks are detected, shut off the engine, allow to cool, and re-torque the affected clamp.

Reassembly

1. Reassembly is performed during the installation steps above
2. Ensure all exhaust clamps are torqued to specification to prevent exhaust leaks
3. Verify all rubber hangers are properly seated to prevent rattles and misalignment

Verification

• Start engine and check for exhaust leaks at both clamp connections with engine at idle and under light throttle
• Visually inspect muffler clearance to surrounding components with engine running (exhaust system will expand slightly with heat)
• Test drive vehicle and listen for any rattles, vibrations, or unusual exhaust notes that would indicate improper installation
• After first 50-100 miles, re-inspect clamp torque and hanger condition to ensure nothing has loosened

More procedures for this vehicle