Exhaust Pipe - Rear Section

Remove and replace the rear exhaust section on a 2008 Dodge Viper 8.4L V10, including disconnecting exhaust hangers and flange connections.

Warnings

Tools required

Parts

• Rear exhaust section assembly × 1 — Use OEM specification or aftermarket equivalent
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust hanger isolators × 2 — Inspect and replace if deteriorated

Preparation

1. Ensure vehicle is on level ground and engine is completely cool
2. Raise vehicle using floor jack at manufacturer-specified lift points
3. Support vehicle securely on jack stands rated for vehicle weight (approximately 3,400 lbs)
4. Apply penetrating oil to all visible exhaust flange bolts and hanger connections, allow to soak for 10-15 minutes
5. Inspect exhaust system for aftermarket modifications that may affect removal procedure

Procedure

1. 1

   Locate rear exhaust section connection points
   Position yourself under the rear of the vehicle. Identify the flange connection where the rear exhaust section connects to the mid-pipe section (verify exact location against factory service documentation for this chassis). Identify the rubber exhaust hangers supporting the rear mufflers and tailpipes. On the 2008 Viper, confirm the exact number of rubber hanger isolators supporting the rear section against factory service documentation before proceeding.
2. 2

   Disconnect rear exhaust hangers
   Starting with the rearmost hanger, use a pry bar or large flathead screwdriver to carefully separate the exhaust hanger rod from the rubber isolator bushing. Apply steady pressure to work the rod out of the rubber grommet. The rubber may be stiff; avoid tearing it if reusing. Repeat for the second hanger moving forward. Support the exhaust section with one hand or have an assistant hold it as you disconnect hangers.
3. 3

   Remove exhaust flange bolts
   Locate the flange connection between the mid-pipe and rear section. Remove the flange bolts (verify exact bolt count and wrench size against factory service documentation). Hold the nut on one side with the wrench while turning the bolt from the other side with the ratchet and socket. If bolts are severely corroded, apply additional penetrating oil and allow to soak, or carefully apply heat with a torch if safe to do so. Remove both bolts and retain hardware if reusing.
   ⚠Flange bolts may be corroded and difficult to remove. If bolt breaks, the stud will need to be extracted or the flange replaced.
4. 4

   Separate exhaust flange connection
   With bolts removed, carefully separate the flange connection. The flange may be stuck due to carbon buildup and corrosion. Gently twist and pull the rear section away from the mid-pipe flange. Use a pry bar if needed to carefully separate the flanges, being careful not to damage the flange surfaces. The old gasket will likely remain stuck to one or both flanges.
5. 5

   Lower and remove rear exhaust section
   With all connections disconnected, carefully lower the rear exhaust section. The assembly is heavy (approximately 40-50 lbs) and includes the rear mufflers and exhaust tips. Maneuver the assembly to clear the undercarriage components, diffuser, and body work. Remove the exhaust section from under the vehicle. Use caution to avoid striking the rear diffuser or valance during removal.
6. 6

   Clean flange surfaces
   Use a wire brush to thoroughly clean the mid-pipe flange surface where it mates to the rear section. Remove all traces of the old gasket material, carbon deposits, and corrosion. Clean surface should be flat and smooth to ensure proper seal with new gasket. Inspect flange for cracks or damage; replace if compromised.
7. 7

   Inspect exhaust hangers and hardware
   Inspect the rubber hanger isolators on the chassis for cracks, tears, or excessive deterioration. Replace any damaged isolators. Check the condition of the flange bolts and nuts; replace if threads are damaged or excessively corroded. Inspect the new rear exhaust section to ensure all components are present and undamaged.
8. 8

   Install new exhaust flange gasket
   Position the new exhaust flange gasket onto the mid-pipe flange. Ensure the gasket is properly oriented and sits flat against the flange surface. The gasket may have alignment features or tabs to ensure correct positioning.
9. 9

   Position rear exhaust section
   Lift the new rear exhaust section into position under the vehicle. Align the forward flange with the mid-pipe flange and gasket. Maneuver the section to approximate alignment with the exhaust hanger mounting points. This step may require an assistant due to weight and awkward positioning. Ensure exhaust tips are positioned correctly relative to rear valance cutouts.
10. 10

    Install flange bolts finger-tight
    Insert the flange bolts through the flange connection (matching the confirmed bolt count). Thread nuts onto bolts and tighten by hand until finger-tight. Do not fully tighten at this stage to allow for alignment adjustment. Ensure gasket remains properly positioned between flanges.
11. 11

    Connect exhaust hangers
    Align the exhaust hanger rods with the rubber isolator bushings on the chassis. Use a pry bar or screwdriver to help stretch the rubber and work the hanger rod into the isolator grommet. Start with the forward hanger, then move to the rear. The exhaust section should be supported by the hangers with even weight distribution. Check that exhaust tips are centered in the rear valance cutouts and have adequate clearance.
12. 12

    Tighten flange bolts
    With exhaust section properly positioned and hanging correctly, tighten the 2 flange bolts. Use a wrench of the correct size to hold the nut while tightening the bolt with a matching socket and ratchet (verify fastener size against factory service documentation). Tighten bolts evenly in an alternating pattern to ensure even compression of the gasket. Tighten to the factory-specified torque (verify exact value against factory service documentation) in an alternating pattern until the gasket is evenly compressed. Verify flange connection is tight with no gaps.
13. 13

    Verify exhaust clearances
    Inspect the entire rear exhaust section for proper clearance to chassis components, rear transaxle/differential, suspension components, rear diffuser, and body panels. Pay particular attention to exhaust tip position in rear valance cutouts. Gently move exhaust by hand to verify adequate clearance during suspension movement. Adjust hanger positions if necessary to optimize clearance.

Reassembly

1. Reassembly is covered in the installation steps above
2. Double-check all flange bolts are tight and exhaust hangers are fully seated
3. Verify exhaust tips are centered and have proper clearance in rear valance cutouts

Verification

• Start engine and listen for exhaust leaks at the flange connection (hissing or ticking sound)
• Visually inspect flange connection while engine is running for signs of exhaust gas escaping
• Rev engine slightly and verify exhaust note is normal with no rattles or contact sounds
• Check exhaust tips remain centered during engine vibration
• After test drive, re-inspect flange bolts for tightness and check for any contact marks on undercarriage or body panels

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