Chrysler Full-Size Trucks 1967-1988 Repair Guide

Muffler and Outlet Pipes


See Figures 1, 2 and 3


The following applies to exhaust systems using clamped joints. Some models, use welded joints at the muffler. These joints will have to be cut. Always use new gaskets during installation. It is also wise to purchase new clamps or hangers

  1. Raise and support the truck on jackstands.
  3. Remove the U-clamps securing the muffler and outlet pipe.
  5. Disconnect the muffler and outlet pipe bracket and insulator assemblies.
  7. Remove the muffler and outlet pipe assembly. It may be necessary to heat the joints to get the parts to come off. Special tools are available to aid in breaking loose the joints. Discard any old exhaust pipes, or mufflers, along with any clamps or rusty nuts and bolts that are not usable again.
  9. On Crew Cab models, remove the extension pipe.

For rod and insulator type hangers, apply a soap solution to the insulator surface and rod ends to allow easier removal of the insulator from the rod end. Don't use oil-based or silicone-based solutions since they will allow the insulator to slip back off once it's installed.

To install:
  1. Assemble the muffler and rear exhaust pipes together, along with supports and clamps before installing.
  3. Install the components making sure that all the components in the system are properly aligned before tightening any fasteners. Make sure all tabs are indexed and all parts are clear of surrounding body panels.

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Fig. Fig. 1: Dual exhaust system for heavy duty trucks

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Fig. Fig. 2: Exhaust system for sport utility models with V8 engines-1986-88

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Fig. Fig. 3: Common types of brackets and hangers for exhaust systems