Inexpensive Exhaust System

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Inexpensive Exhaust System

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Mustang Forum >> Ford Mustang Tech >> 6 Cyl (V6) Applications >> Inexpensive Exhaust System

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Inexpensive Exhaust System - 4/10/2006 9:18:35 PM

Hotrods_n_Booze

Posts: 13193
Joined: 12/29/2003
From: Southern California
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This step by step tech article was provided by amrcnidyot
Thank you Matt.

Poor Man’s exhaust
2000 V6
Tools Needed
1. Ramps or a lift
2. Ratchet w/ an extender.
3. 15mm 14mm 10mm Sockets
4. Hack saw or something to cut old exhaust out.
5. WD-40
6. 2 flat head screw drivers
7. Safety glasses

Parts Needed
1. Muffler of you choice. I used a Force muffler from summit racing.
2. 2¼ in. turn down
3. 2 2½ in. muffler clamps
4. 2¼ muffler clamp
5. Universal wire exhaust hanger from autozone

Price
1. Muffler - $39 shipped at summitracing.com
2. Turndown - $5 to $7
3. 3 Muffler clamps - about $5
4. Universal Hanger about $5

I forgot to put the turndown in but it’s the pipe on the right of the pic.

The first thing you need to do is make sure your hacksaw, if that is what you are using, has a new blade. Don’t make my mistake and think the blade looks fine then spend forever trying to cut through an exhaust pipe only to find out after you cut the first pipe that the blade is bad.

Now you need to put your car up on a couple of ramps or if you have access to a hydraulic lift I would use that. Be sure to use the parking brake and put a pair of wheel chocks behind the wheels after you have it up one the ramps.

Now you need to make your first cut using the hacksaw. Make the cut as close to the muffler as you can so that the new muffler will fit in place nicely. This cut will be on the inlet side of the muffler. (The side facing the front of the car) If your using the ramps, for a right handed person it is probably easier to lay under the passenger side and cut, and for a left handed person it will probably be easier one the drivers side.

After you have the muffler cut off you can start removing the exhaust hangers. The first one I did was the one in the very back. The easiest way to get to it is lying right behind the driver side rear wheel. The other hanger is like 2 hangers in 1. It holds the muffler and the pipe right behind the muffler, and it is located on the outlet side of the muffler. I screwed up and didn’t take a picture of the hangers before I took them off but I do have pics of them after I took them off. The first picture is the rear hanger and the left side of the picture is the front of the car and the right is the back. The second picture is the muffler hanger. The rear hanger has 2 15mm bolts holding it up and the other one has 2 10mm bolts holding it up. You also might want to find something to hold up the muffler while you take off the hangers.

Now that the exhaust from the muffler back is not attached to the car you can get to the 2nd place you need to cut easier.

The 2nd place you need to cut is about half a foot up the outlet pipe coming out of your muffler. This is so you can get the pipes out from under the car because right now they curve above the rear axle and it would be impossible to get the pipes out without making another cut or dropping the axle.

After you make that cut, the muffler will slide right out from under the car and to get the tailpipe out you will need to turn and maneuver it around until you can figure out how to get it out. I turned the bent end towards the passenger side of the car and messed around with it until it came out. It really isn’t too hard to do.

The old exhaust.

Now you will need to remove the exhaust hanger from the muffler. I don’t really know what the best way to do this is but I sprayed WD-40 around the rubber pieces and used 2 flat head screw drivers to pry under the rubber on each side of the metal hanger and then I pulled the rubber off of the metal using my hands.

Now that you have the hanger off you can slide the universal hanger in the rubber piece on the shorter metal side of the hanger. See the picture for more detail.

You can now bolt that hanger back where it was before.
Now you can put the turndown inside the outlet of the muffler and use one of the 2½ in. clamps to tighten it down really tight.

Now you will want something to hold up the muffler as you bolt it in. Slide the inlet side of the muffler into the first pipe that you cut and clamp it down pretty tight but not all of the way using the other 2½ in. muffler clamp. Now use the 2¼ in. muffler clamp to put around your turndown then into the universal hanger and tighten in down pretty tight. Now make sure everything is where you want it and finish tightening down all of the clamps.

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