Muffler

Replacement of the rear muffler assembly on a 2008 Dodge Viper, including disconnection from the exhaust system and removal of hanger brackets.

Warnings

Tools required

Parts

• Muffler assembly × 1 — Use OEM specification or aftermarket equivalent
• Exhaust clamp (if reusing is not possible) × 2 — OEM P/N 68003912AA or equivalent
• Rubber exhaust hangers (if deteriorated) × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake.
2. Place wheel chocks behind front wheels.
3. Allow exhaust system to cool completely (minimum 1 hour after last operation).
4. Raise rear of vehicle using floor jack at rear differential housing or approved lift points.
5. Support vehicle securely on jack stands rated for vehicle weight (minimum 3,000 lbs per stand). Never work under a vehicle supported only by a floor jack.
6. Inspect exhaust system for corrosion and apply penetrating oil to all clamp bolts and hanger bracket fasteners. Allow 10-15 minutes to penetrate.

Procedure

1. 1

   Locate and inspect muffler assembly
   Position yourself under the rear of the vehicle with adequate lighting. The muffler assembly is located behind the rear axle, with inlet pipes connecting forward to the catalytic converters and dual outlet tips extending rearward. Identify the two inlet clamp connections, two rubber exhaust hangers supporting the muffler body, and hanger bracket mounting bolts at the rear of the assembly. Visually inspect for excessive corrosion that may complicate removal.
2. 2

   Disconnect driver side inlet clamp
   Locate the band clamp connecting the driver side inlet pipe to the muffler assembly. Using a 15mm socket, loosen the clamp bolt completely but do not remove it yet. Once loosened, the clamp should expand slightly. If the clamp is seized, apply additional penetrating oil and allow to soak, then retry. Do not force rusted clamps; if bolt breaks, clamp will need replacement.
3. 3

   Disconnect passenger side inlet clamp
   Repeat the clamp loosening process for the passenger side inlet connection using a 15mm socket. Loosen the clamp bolt completely to allow separation. With both inlet clamps loosened, the muffler should have some forward-to-back movement.
4. 4

   Remove rear hanger bracket bolts
   Locate the rear hanger bracket that supports the outlet tips. This bracket is secured to the underbody with 2 bolts. Using a 13mm socket, remove both hanger bracket mounting bolts completely and retain hardware if reusing bracket. The muffler assembly will now be supported only by the two rubber hangers on the muffler body.
5. 5

   Support muffler assembly
   Position a floor jack or have an assistant support the weight of the muffler assembly from below. The assembly weighs approximately 35-40 lbs and will drop once the rubber hangers are released. Ensure adequate support before proceeding to prevent the muffler from falling and causing injury or damage to surrounding components.
6. 6

   Release rubber exhaust hangers
   Using an exhaust hanger removal tool or pry bar, carefully pry each rubber hanger off its mounting stud on the underbody. The Viper muffler has two hangers supporting the main body. Work one hanger at a time, pulling the rubber isolator away from the stud while supporting the muffler weight. If hangers are deteriorated or torn, plan to replace during installation.
7. 7

   Separate inlet pipes and remove muffler
   With the muffler now free from hangers and supported, pull the muffler rearward to separate the inlet pipes from the clamp connections. The pipes may be stuck due to carbon buildup; gently twist and pull to separate. Once inlet pipes are clear of clamps, lower the muffler assembly carefully and remove from under the vehicle. Take care not to damage surrounding heat shields or fuel tank shield during removal.
8. 8

   Clean and inspect mounting points
   With the muffler removed, use a wire brush to clean the inlet pipe ends, clamp surfaces, and rubber hanger mounting studs. Inspect studs for damage or excessive rust. Check that rubber hangers on the new muffler are intact and properly positioned. Inspect the hanger bracket for damage; replace if bent or cracked. Clean clamp bolt threads and apply anti-seize compound to prevent future corrosion.
9. 9

   Position new muffler assembly
   With assistance or using a floor jack, lift the new muffler assembly into approximate position under the vehicle. Align the inlet pipes with the forward exhaust clamps, leaving approximately 1-2 inches of clearance initially. Do not force connections; verify correct orientation with outlets facing rearward and hangers positioned toward their mounting studs.
10. 10

    Install rubber exhaust hangers
    Using an exhaust hanger tool or pry bar, stretch each rubber hanger over its corresponding mounting stud on the underbody. Work one hanger at a time while supporting the muffler. Ensure hangers are fully seated on the studs and not twisted. The muffler should hang naturally once both hangers are installed, with inlet pipes aligned with forward connections.
11. 11

    Connect inlet pipe clamps
    Slide the muffler forward so that inlet pipes fully engage into the band clamp connections (approximately 2-3 inches of overlap). Position the driver and passenger side band clamps so they cover the joint between pipes. Hand-tighten both clamp bolts using a 15mm socket until snug, but do not torque yet. Verify pipes are fully seated and muffler hangs level before final tightening.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
12. 12

    Install rear hanger bracket
    Position the rear hanger bracket to support the outlet tips and align with underbody mounting holes. Install the 2 bracket bolts and hand-tighten using a 13mm socket. Verify the muffler sits level and outlet tips are properly aligned before torquing bolts.
    Torque spec

    Hanger Bracket Bolts25 Nm (18 lb-ft)
13. 13

    Torque all fasteners to specification
    Using a torque wrench, tighten the rear hanger bracket bolts to the manufacturer-specified value (verify against 2008 Viper service manual; approximately 25 Nm / 18 lb-ft). Then torque both inlet clamp bolts to the manufacturer-specified value (verify against 2008 Viper service manual; typical exhaust band clamps are approximately 35 Nm / 26 lb-ft). Verify all connections are tight and muffler is securely mounted with no excessive movement.
    Torque spec

    Hanger Bracket Bolts25 Nm (18 lb-ft)

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

    Verify clearances and alignment
    Visually inspect the installed muffler for adequate clearance from the rear differential, fuel tank shield, underbody panels, and rear suspension components. Verify minimum 1 inch clearance at all points. Check that outlet tips are symmetrically positioned and aligned with bumper cutouts. Gently push on muffler to verify hangers are secure and allow proper movement without contact.

Reassembly

1. Reassembly is integrated into the installation steps above.
2. Ensure all clamps and bracket bolts are torqued to specification.
3. Verify rubber hangers are fully seated and not twisted on mounting studs.
4. Confirm outlet tips are centered in rear bumper openings with adequate clearance.

Verification

• Lower vehicle from jack stands and remove wheel chocks.
• Start engine and allow to idle. Listen for exhaust leaks at inlet clamp connections; there should be no hissing or excessive noise.
• Rev engine to 2,000-3,000 RPM and listen again for leaks or rattles. Exhaust note should be consistent without popping or misfires indicating leaks.
• Visually inspect all connections while engine is running (from a safe distance) for visible exhaust gas escaping from joints.
• Take vehicle for short test drive and verify no exhaust odors enter cabin, no rattles or vibrations from exhaust system, and normal engine performance.
• After test drive, allow exhaust to cool and perform final visual inspection under vehicle for any signs of contact, leaks, or misalignment.

More procedures for this vehicle