Chrysler Full-Size Trucks 1989-1996 Repair Guide

Front Header Pipes, Catalytic Converter and Inlet Pipes



See Figures 1, 2, 3 and 4

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. Disconnect the front exhaust pipe flange or flanges for V engines, nuts and bolts connected to the exhaust manifold.
  5. Loosen and remove any bolts to the catalytic converter (if equipped), or the flange prior to the muffler. If your system has no flanges all the way to the end of the exhaust, you will either have to cut the exhaust where you are replacing the piece, or replace the unit as an assembly.
  7. Most aftermarket parts suppliers have your exhaust in cut sections, (unlike your original exhaust). It is wise to look at your exhaust before cutting any pipe if you are not purchasing your exhaust parts from the dealer.
  9. Remove the pipe assembly. It may be necessary to heat the joints to separate the parts. Special tools are available to aid in breaking loose the joints. Discard any old pipes, and any clamps or rusty nuts and bolts.

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. Install the front header pipe with new exhaust nuts and gaskets. Attach the catalytic converter (if equipped) at the flange of the header pipe and tighten. Install any rear exhaust pipes together, along with supports and clamps.
  3. Make sure that all the system components are properly aligned before tightening fasteners. Make sure all tabs are indexed and all parts are clear of surrounding body panels.

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Fig. Fig. 1: A common exhaust system-Dakota models

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Fig. Fig. 2: Common exhaust systems-full-size trucks

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Fig. Fig. 3: Common exhaust system components-5.9L heavy duty and 8.0L engines

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Fig. Fig. 4: Common exhaust system components-diesel engine