Resonator

Remove and replace the exhaust resonator assembly on a 2005 Dodge Viper 8.3L V10, including disconnection of exhaust clamps and rubber hangers.

Warnings

Tools required

Parts

• Exhaust resonator assembly × 1 — Use OEM specification or aftermarket equivalent
• Exhaust clamps (if corroded) × 2 — Use OEM specification
• Rubber exhaust hangers (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and apply parking brake.
2. Place wheel chocks behind front wheels.
3. Allow exhaust system to cool completely (minimum 1 hour after engine operation).
4. Apply penetrating oil to all exhaust clamp bolts and allow to soak for 10-15 minutes.
5. Raise rear of vehicle using floor jack at rear differential housing or approved lift point.
6. Support vehicle securely on jack stands positioned under rear axle tubes near differential.
7. Verify vehicle stability before working underneath.

Procedure

1. 1

   Locate resonator assembly
   Position yourself under the rear center section of the vehicle. The resonator is located between the catalytic converters and the rear muffler assembly, approximately beneath the passenger compartment. Identify the inlet connection (forward, connecting to cats) and outlet connection (rearward, connecting to muffler).
2. 2

   Support resonator assembly
   The resonator weighs approximately 15-20 lbs. Position a floor jack or jack stand under the resonator body to support its weight during removal. Raise just enough to take weight off the rubber hangers but not to lift the vehicle.
3. 3

   Remove forward exhaust clamp
   Locate the band clamp connecting the resonator inlet to the catalytic converter outlet pipes. Using the appropriate socket (verify size against factory documentation), loosen and remove the clamp bolt. The clamp uses a single bolt with nut. If severely corroded, apply additional penetrating oil and use a wire brush to clean threads. Remove the clamp completely.
   Torque spec

   Exhaust Clamps55 Nm (41 lb-ft)
4. 4

   Remove rearward exhaust clamp
   Locate the band clamp connecting the resonator outlet to the muffler inlet pipe. Using a 15mm socket, loosen and remove the clamp bolt. Remove the clamp completely. Note the orientation of clamps for reinstallation.
5. 5

   Disconnect forward rubber hanger
   Locate the rubber exhaust hanger supporting the forward section of the resonator. The hanger attaches between a metal tab welded to the resonator and a metal hook on the chassis. Using a pry bar or by hand, work the rubber grommet off the chassis hook. Push or twist the hanger to release it. Inspect rubber for cracking or deterioration.
6. 6

   Disconnect rearward rubber hanger
   Locate the rubber exhaust hanger supporting the rearward section of the resonator. Using the same technique as the forward hanger, release the rubber grommet from the chassis hook. The resonator should now be free of all mounting points.
7. 7

   Separate resonator from exhaust system
   With the clamps removed, carefully work the resonator inlet pipe out of the catalytic converter outlet connection. This is a slip-fit joint. Twist and pull gently while supporting the weight with the floor jack. Once the forward connection is free, pull the resonator rearward to separate the outlet pipe from the muffler inlet. Lower the jack and remove the resonator from under the vehicle.
8. 8

   Inspect connection points
   With the resonator removed, inspect the catalytic converter outlet pipes and muffler inlet pipe for damage, excessive corrosion, or carbon buildup. Use a wire brush to clean the pipe ends where the new resonator will connect. Check that pipe ends are round and not crushed. Inspect all rubber hangers on the vehicle for cracking or deterioration and replace if necessary.
9. 9

   Position new resonator
   Apply a thin coat of penetrating oil or anti-seize to the outer surface of the catalytic converter outlet pipes (this aids future disassembly). Position the new resonator on a floor jack and raise into approximate position. Align the inlet end with the catalytic converter outlets first.
10. 10

    Connect inlet to catalytic converters
    Slide the resonator inlet pipe over the catalytic converter outlet pipes. The connection should slip together with moderate effort. Twist the resonator slightly if needed to align. The pipes should overlap by approximately 2-3 inches. Do not install the clamp yet.
11. 11

    Connect outlet to muffler
    With the inlet connection in place, slide the resonator outlet pipe into the muffler inlet pipe. Again, this is a slip-fit connection requiring moderate effort. Ensure approximately 2-3 inches of overlap. Adjust the resonator position forward or rearward until both connections have proper overlap.
12. 12

    Install rubber hangers
    With the resonator positioned, install the forward rubber hanger by working the rubber grommet onto the chassis hook. Use a pry bar if needed to stretch the rubber over the hook. Install the rearward rubber hanger in the same manner. The hangers should support the resonator with slight tension, keeping pipes aligned.
13. 13

    Install forward exhaust clamp
    Position the band clamp around the joint between the catalytic converter outlet and resonator inlet. Ensure the clamp is centered over the joint with equal overlap on both pipes. Start the clamp bolt by hand, then tighten to the factory-specified torque value (verify against service documentation) using the appropriate socket and torque wrench. Verify the joint remains properly aligned after tightening.
    Torque spec

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

    Install rearward exhaust clamp
    Position the band clamp around the joint between the resonator outlet and muffler inlet. Center the clamp over the joint. Tighten to specification using a 15mm socket and torque wrench. Check that all exhaust components hang level with no visible stress or misalignment.
    Torque spec

    Exhaust Clamps55 Nm (41 lb-ft)
15. 15

    Remove support and lower vehicle
    Remove the floor jack from under the resonator. Visually inspect all connections and hangers one final time. Lower the vehicle from the jack stands. Remove wheel chocks.

Reassembly

1. Installation is covered in the removal steps above.
2. Ensure all exhaust clamps are torqued to specification to prevent exhaust leaks.
3. Verify rubber hangers are properly seated on chassis hooks with adequate tension.

Verification

• Start the engine and allow to idle. Listen for exhaust leaks at the resonator connections. A hissing or ticking sound indicates a leak requiring clamp re-torquing or repositioning.
• With engine running, visually inspect the resonator area for escaping exhaust gases (visible as heat shimmer or vapor).
• Rev engine to 2500-3000 RPM briefly and listen for rattles or contact between exhaust components and chassis/body.
• After initial test, allow engine to cool and re-check all clamp torque values.
• Test drive vehicle and verify no exhaust noise, vibration, or exhaust smell in cabin.
• After 50-100 miles of driving, re-inspect clamp tightness and hanger condition.

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