2015-2023 Charger & Challenger Muffler: Engine Fitment & Active Exhaust Guide

Variant Differences: Engine-Specific Exhaust Systems

The single most important factor when replacing a muffler on a 2015-2023 Dodge Charger or Dodge Challenger is the engine. Dodge produced entirely different exhaust systems for each powertrain, and the parts are not interchangeable. Using a muffler from a different engine will result in poor fitment, drone, and potential performance issues.

• 3.6L V6 (SXT, GT): These models feature a quieter, more restrictive exhaust system designed for daily driving. The piping diameter is smaller than on V8 models. Many owners who modify these systems report undesirable rasp or drone.
• 5.7L V8 (R/T): This is the entry-level V8 system. Later models often include an Active Exhaust system as an option. Part number 68453193AC is commonly associated with the 5.7L engine.
• 6.4L V8 (Scat Pack, SRT 392): These models come standard with a dual-mode Active Exhaust system. The mufflers contain valves that open for a louder, more aggressive sound. Part number 68516699AA is associated with the 6.4L engine.
• 6.2L Supercharged V8 (Hellcat, Redeye): This system is designed for maximum flow and also uses an Active Exhaust system, tuned for the unique sound of the supercharged engine.

Understanding the Active Exhaust System

Found on most 6.4L and 6.2L models (and optional on some 5.7L models), the Active Exhaust system uses electronically controlled butterfly valves located in the rear mufflers. These valves are managed by the car's computer. In normal driving or when the engine's Multi-Displacement System (MDS) is active, the valves remain closed for a quieter ride. Under hard acceleration or when Sport/Track mode is selected, the valves open, allowing exhaust to bypass some of the muffler chambers for a significantly louder, more aggressive tone. These valves are a common point of failure.

Known Issues & TSBs

Active Exhaust Valve Rattle or Squeak

The most common reported issue is a metallic rattle or a high-pitched squeak from the rear of the car, especially at low speeds or on startup. This is almost always caused by the actuator or the butterfly valve mechanism inside the muffler. The moving parts can wear, corrode, or the spring can lose tension, causing it to vibrate.

• Temporary Fix: Many owners have had success temporarily silencing a squeaky valve by spraying a dry lubricant (like a PTFE-based spray) into the actuator shaft where it enters the muffler body. This is not a permanent solution, as the heat will eventually burn off the lubricant.
• Permanent Fix: The official repair is to replace the entire muffler assembly. A common modification is to perform an "active exhaust delete" by cutting out the valves and welding in a straight pipe. However, simply unplugging the valve actuators will cause a Check Engine Light and may disable remote start. To prevent this, electronic "valve simulators" must be plugged into the factory wiring harness to send a correct signal back to the computer.

Technical Service Bulletins (TSBs)

Chrysler issued TSB 18-035-15 REV. B for some 2015 Dodge Challenger and Charger models with the 6.2L engine. This bulletin addresses a software update for the Powertrain Control Module (PCM) to correct issues that could trigger active exhaust valve performance codes, specifically P1217 and P121B. If you have these codes, a dealer may need to flash your PCM before replacing parts.

Recalls

As of this writing, there are no active NHTSA recalls specifically for the mufflers on 2015-2023 Dodge Charger or Challenger models.

Symptoms of a Failing Muffler

Buying a Used Muffler: What to Check

A used OEM muffler can be a great value, especially since many are replaced for performance upgrades while still in good condition. However, careful inspection is key.

1. Verify Engine Compatibility: This is the #1 rule. Get the part number from the seller or clear photos to match it to your engine (3.6L, 5.7L, 6.4L, 6.2L). A muffler for a 6.4L Scat Pack will not fit a 3.6L SXT correctly.
2. Check for Internal Rattles: Pick up the muffler and shake it vigorously. If you hear anything rattling or sliding around inside, the internal baffles have failed. Do not buy it.
3. Inspect for Rust and Corrosion: Look closely at the welded seams, inlet/outlet pipes, and hanger brackets. Surface rust is normal, but avoid anything with deep pitting, flaking metal, or visible cracks.
4. Look for Dents and Damage: Check the muffler body for large dents or scrapes that could indicate internal damage or restricted flow.
5. For Active Exhaust Models: If buying a muffler with an active exhaust valve, manually move the valve linkage by hand. It should move smoothly without binding. Check the electronic actuator for any cracks or signs of water damage.

Replacement Cost Breakdown

The cost to replace a muffler on a Charger or Challenger varies dramatically based on the engine and what parts are being replaced.

Replacement Overview

• Difficulty: 3/5 (Moderate)
• Time: 1.5 - 2.5 hours
• DIY Feasible: Yes, for a mechanically inclined person with the right tools.

Replacing the mufflers is generally a bolt-off, bolt-on procedure. However, rusted bolts and stubborn rubber exhaust hangers can make the job difficult. The car will need to be safely raised on jack stands or a lift. The most difficult part is often removing the old rubber hangers, which can be done with a specialized hanger removal tool or a combination of pry bars and silicone spray lubricant. The system is typically loosened at a clamp or flange connection forward of the mufflers, then removed from the hangers.

Frequently Asked Questions