How to Replace Exhaust 05-10 Chrysler 300

Difficulty: Intermediate · About 90 min · Chrysler 300

Replace the exhaust assembly on a 2005–2010 Chrysler 300, supporting the system before releasing hangers and flanges.

Steps

1. Raise and support the vehicle

   Let the exhaust cool completely, then raise the vehicle on a lift or secure it on jack stands at approved points. Apply penetrant to corroded exhaust hardware and identify the oxygen sensor connectors and hanger locations.

2. Disconnect sensors and release the exhaust

   Unplug the oxygen sensor connectors and move the wiring clear. Remove the heat shield and flange fasteners, support the exhaust with a helper and straps, then release the hanger bushings and crossmember fasteners before lowering the assembly.

3. Position the replacement exhaust

   Transfer sensors only if required, using the correct sensor socket and avoiding wire twisting. Lift the replacement into position with support straps, align flanges and hangers, and start all fasteners by hand with new gaskets where specified.

4. Secure and inspect the system

   Tighten flange and bracket fasteners to the vehicle specification, reinstall the heat shield, and seat each rubber hanger fully. Reconnect sensor plugs, remove supports, start the engine, and check for leaks or contact while keeping clear of hot exhaust parts.

Check your vehicle’s repair manual for exact specifications and fit.