Chrysler Concorde 1998-2004 Exhaust System Bolt Torque Specifications & Gasket Sealing
Chrysler Concorde 1998-2004

Chrysler Concorde 1998-2004 Exhaust System Bolt Torque Specifications

Detailed torque specifications for exhaust manifold, pipe, and muffler bolts on the 1998-2004 Chrysler Concorde.

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

Search Specifications

Search by component name, bolt size, or description

Torque Calculator

Convert between different torque units

Exhaust Manifold

This section includes the torque specifications for components directly attached to the engine cylinder head, including the exhaust manifold or headers.

1

Exhaust Manifold to Cylinder Head Bolts

M10 x 1.5
Torque Value
20 ft-lbs (27 N·m)
Important Notes
Tighten bolts in a spiral pattern, starting from the center and working outwards. Always use new gaskets.

Front Exhaust Pipe

This section covers the torque specifications for components connected to the exhaust manifold, typically the front exhaust pipe (downpipe).

1

Exhaust Pipe to Exhaust Manifold/Headers Bolts/Nuts

M10 x 1.5
Torque Value
20 ft-lbs (27 N·m)
Important Notes
Ensure proper alignment of the exhaust pipe and use new gaskets. This connection often uses studs with nuts.

Catalytic Converter

This section details the torque specifications for the catalytic converter and its connections to the exhaust system.

1

Catalytic Converter to Exhaust Pipe Bolts/Nuts

M10 x 1.5
Torque Value
25 ft-lbs (34 N·m)
Important Notes
Use new gaskets for a proper seal. Tighten evenly to prevent leaks.

Intermediate Exhaust Pipe

This section covers torque specifications for connections between sections of exhaust piping, such as to the resonator or intermediate pipes.

1

Exhaust Pipe Flange Bolts/Nuts Between Exhaust Sections

M10 x 1.5
Torque Value
25 ft-lbs (34 N·m)
Important Notes
Use new gaskets. Tighten evenly to avoid leaks. This applies to connections before and after the resonator or intermediate pipe.

Muffler

This section provides torque specifications for the muffler and its connections to the exhaust system.

1

Muffler to Exhaust Pipe Bolts/Nuts

M10 x 1.5
Torque Value
25 ft-lbs (34 N·m)
Important Notes
Use new gaskets or clamps as required. Tighten fasteners evenly to prevent exhaust leaks.

Exhaust Hangers

This section details the torque specifications for the bolts and nuts securing the exhaust hangers to the chassis.

1

Exhaust Hanger Bolts/Nuts to Chassis

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
Ensure proper alignment of the rubber hangers before tightening. Estimated value based on typical M8 bolt torque. Do not over-tighten.

Oxygen Sensor

This section covers the torque specification for the oxygen sensor when installed into the exhaust manifold or pipe.

1

Oxygen Sensor Torque to Exhaust Pipe/Manifold

M18 x 1.5
Torque Value
32 ft-lbs (43 N·m)
Important Notes
Do not over-torque; this can damage the sensor. Use anti-seize compound on threads.

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

Why is it important to use the correct torque specifications for exhaust bolts?

Using the correct torque specification is crucial to ensure a proper seal and prevent exhaust leaks. Over-tightening can stretch or break bolts, damage gaskets, and warp flanges, while under-tightening may cause leaks and allow bolts to loosen over time. Both can lead to exhaust noise, reduced performance, and potential carbon monoxide hazards. For example, over-tightening the bolts connecting the exhaust manifold to the cylinder head could crack the manifold, requiring expensive repairs.

Q2

What happens if I overtighten exhaust bolts?

Overtightening exhaust bolts can lead to several problems, including: stretching or breaking bolts, damaging exhaust gaskets (leading to leaks), warping exhaust flanges (causing a poor seal), and even cracking exhaust manifolds or pipes. For example, overtightening a bolt on the exhaust flange connecting to the catalytic converter could warp the flange, requiring you to replace both the flange and possibly the catalytic converter itself.

Q3

Can I reuse exhaust gaskets?

It is generally not recommended to reuse exhaust gaskets. These gaskets are designed to compress and form a seal; once compressed, they may not provide an adequate seal again, leading to leaks. Always replace exhaust gaskets when removing and reinstalling exhaust components. For instance, reusing the exhaust manifold gasket after removing the manifold to address an issue will often result in leaks at that point.

Q4

What should I do if an exhaust bolt breaks?

If an exhaust bolt breaks, it needs to be extracted. Depending on the situation, you may need to use a bolt extractor, drill the bolt out carefully, or seek professional help. Attempting to force a broken bolt out can damage the threads in the manifold or exhaust pipe and require even more complex repairs. In the case of a broken manifold stud, professional removal is often necessary to prevent further damage.

Q5

Do I need to use anti-seize on exhaust bolts?

Applying anti-seize to exhaust bolts is highly recommended. The heat generated in the exhaust system can cause bolts to rust and corrode, making them extremely difficult to remove later. Anti-seize helps prevent this corrosion, allowing for easier removal in the future, for example when working on the exhaust system to replace a muffler or to address a noise problem. A small amount on the threads is sufficient.

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

Torque Wrench

A precision tool used to apply a specific amount of torque to a fastener.

  • Accurate torque settings
  • Variety of drive sizes (3/8", 1/2")
Learn more

Socket Set

A set of sockets with different sizes to fit various bolt heads.

  • Standard and metric sizes
  • Various drive sizes (3/8", 1/2")
Learn more

Extension Bars

Used to reach fasteners in recessed areas.

  • Different lengths available
  • Provides easier access
Learn more

Penetrating Oil

A lubricant used to loosen rusted or seized bolts.

  • Reduces friction
  • Breaks down rust
Learn more

Safety Glasses

Protective eyewear to prevent eye injuries.

  • Impact resistant
  • Clear lens
Learn more
Service Procedures

Exhaust Manifold Bolt Torque Procedure

Procedure for torquing the bolts on the exhaust manifold of a 1998-2004 Chrysler Concorde.

  • Locate the exhaust manifold bolts.
  • Apply penetrating oil if bolts are rusted or seized.
  • Using the correct size socket, tighten all bolts in the specified sequence gradually.
  • Torque bolts to 25 ft-lbs. Verify the torque with a torque wrench.
View full procedure

Exhaust Pipe Connection Bolt Torque Procedure

Procedure for torquing the bolts at exhaust pipe connections of a 1998-2004 Chrysler Concorde.

  • Locate the exhaust pipe connection bolts.
  • Apply penetrating oil if bolts are rusted or seized.
  • Using the correct size socket, tighten all bolts evenly.
  • Torque the bolts to 20 ft-lbs. Verify the torque with a torque wrench.
View full procedure
Technical Service Bulletins

Exhaust Bolt Corrosion Issues

2001-05-15

This bulletin addresses issues with corroded exhaust bolts on 1998-2004 Chrysler Concorde vehicles, leading to exhaust leaks and difficulty in removal.

1998-2004

Resolution: Use penetrating oil before removal, apply anti-seize compound on bolts during reinstallation and verify the correct torque specifications.

About the Author

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Alan Montanye - Automotive Technical Specialist
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Alan Montanye

Automotive Technical Specialist

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