This project started out when I bought a pair of GT mufflers off of Cascotech on eBay. The right side muffler is a simple bolt-on, and I figured why let the left one go to waste?
To mount the right side muffler, remove the existing muffler (unbolt 3 brackets and the pinch clamp at the exhaust) and mount the new muffler using two of the existing brackets. Save the two bolts from the 3rd bracket. I slipped the muffler over the exhaust pipe loose and bolted the brackets in place, then tightened up the pinch clamp.
The left muffler is a bit more tricky. First I used tracing paper to make a template of the right side opening. I lined the top of the paper with the bodyline on the bumper and made a small registration mark at the license plate opening. Then I cut out the paper at the existing opening (see pic 1).
Next I flipped the paper and lined it up on the left side (see pic 2). I mounted the muffler brackets and held the muffler up to make sure the opening was in the right place before cutting it.
Then using a moto tool with a router bit I carved out the opening (see pic 3). I deburred the edges with a piece of sandpaper.
I mounted the brackets, pic 4 is front and pic 5 is rear. Both pics are taken from the left side. Note that the brackets can mount different than this, but if they aren't installed like this the muffler won't fit right. Ask me how I know this I used the bolts salvaged from the old right side bracket for the new front bracket. These bolts are not yet available from Ford, so for the rear bracket I went to Home Depot and got 8mm- 1 25 x 25mm bolts (zinc plated) and Grade B 5/16" zinc flat washers. This is a perfect match for the existing bolts. Note that the frame rails have UNTAPPED receiver holes for the muffler brackets. I suggest chasing them (screw the bolt in, then remove it) with the existing bolts before installing the new bolts. The existing bolts are easier to get aligned and started.
The brackets are Ford GT muffler brackets, part number 4R3Z-5A246-AA. I recommend getting them from KEvin at Clevenger Ford ( Clevparts@aol.com ). He'll know exactly what you're talking about, and his prices are a lot cheaper than your local Ford dealer.
Next I slipped the muffler into the brackets to make sure it fit OK. Everything looked great! So I removed the muffler and stuck it into the trunk. I don't think it would be a good idea to drive the car with the muffler just hung from the brackets as it'll bounce around and could even fall off. The muffler can be removed without removing the brackets at this point, it just slips forward and out of the brackets.
I took the car to Midas and they did the rest. They ran a 2-1/2" pipe from the front of the muffler over the axle and up to the left headpipe. They cut into the headpipe and welded the new pipe to the opening. They had to remove the existing harmonic balancer off of the right pipe. I've driven it about 50 miles and have not noticed any new vibration (it has always had a little vibration right at 2100 RPM, it's still there but not worse).
That's it! Mainly I did this for looks, I really didn't like the single exhaust. This is a Mustang after all! It NEEDS duals, even if it is "just" a 6 It sounds much better than stock, it has a nice, deep V8 sound to it. It's definitely not as loud and throaty as a GT with an aftermarket exhaust, but it sounds very good
Thanks LIVNBIG, glad to help!! I forgot the prices, I just posted them.
The GT bumper is a good idea, that's one way to avoid cutting the stock valance By the way, for anyone else that's interested in a GT bumper mask Cascotech on eBay has those too (prepainted). You might have to email them for availibility. Their parts are takeoffs from GTs that are being converted into Saleens, so the parts are all new.
Tres, very good information on the exhaust. I hope it works well for you. I finally decided and ordered a kit from chronicbump on ebay today. For anyone that's interested, it is item #7976770140. It's a V6 specific cat back system for about $480. I know that may be a little pricey but I wanted to be as sure as I could concerning size. Too little, too much pressure. Too much, too little pressure. This system joins the pipe coming off the existing Y pipe and then splits out into duals with mufflers. I also went ahead and ordered the Steeda cold air intake so I'm hoping to have this all on in a week or so. I have certainly learned a lot from your posts along with several others. I'll be posting pics and try to help anyone I can. Jim
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V6 5-speed Sonic Blue. GT fog lights, Magnaflow dual exhaust, Steeda CAI, X-cal tuner, sequential tail lights, black shorty antenna, flaming horse hood decal.
Thanks LIVNBIG, glad to help!! I forgot the prices, I just posted them.
The GT bumper is a good idea, that's one way to avoid cutting the stock valance By the way, for anyone else that's interested in a GT bumper mask Cascotech on eBay has those too (prepainted). You might have to email them for availibility. Their parts are takeoffs from GTs that are being converted into Saleens, so the parts are all new.
Yeah, I think the TAKE-OFF's are the way to go if you're gonna swap bumpers, that's what I have! It's an EXACT match color and all!
Those bracket's are expensive little suckers!!!!
< Message edited by LIVNBIG -- 6/4/2005 11:48:18 PM >
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06 Mustang GT, Performance White, IUP, Charcoal Leather, AT 97 C5 Corvette, Arctic White
==I finally decided and ordered a kit from chronicbump on ebay today. For anyone that's interested, it is item #7976770140==
I've seen a few posts about the Magnaflow system, those that have it seem to be quite happy with it!
==Those bracket's are expensive little suckers!!!!==
They are, but the muffler hangs in exactly the same place as on the GT if you use them. One person skipped the brackets and had his muffler shop fabricate hangars, but they had trouble getting the muffler to hang in exactly the right spot (it was too low and too far towards the front of the car). Another person removed the front bracket off the right muffler and used it as a rear brackets on the left (it's the same bracket). Then he had a shop fabricate hangars for the front of both mufflers. That way he was able to get the mufflers to hang right without having to buy the left side brackets. Not a bad idea if you want to save 70 bucks! Who's sunroof do you have on yours? It looks nice!
==Treeeessss your such a pimp!!!==
LOL! Well I have always like those hats
==That looks great!!! I'm jealous, that is my next mod, once I find the time and money. Moreso, the time. ==
Thanks! It wasn't too bad time-wise, I spent about an hour yesterday morning doing the prepwork and then dropped it off. It took the shop about 2 hours to do the pipe, we just went and had lunch and ran some errands while they did that.
==Yes...you are the man. Thanks for posting the pic and the how-to-do! ==
You're quite welcome, hope it helps! All the info was in these forums already, but it's spread out all over the place. I'm going to try to take some pics of the pipe tie-in, it would have been good to catch it on the lift but it was down by the time I got there.
Steve, thanks again! I like that sunroof a lot, don't see many Mustangs with them. I was really surprised it wasn't offered as an option, but then again I don't remember the last time they put one on a 'stang. Great job on the GT front end too! Very nice looking.
i am extremely happy the way my car performs with the true duals. i spent a lot of time on two lane roads in Tennessee saturday and in third gear passing it really hauls. first time i passed i lookd down and was doing 80 with no strain. have K&N too that helps even more. it runs as good in the upper RPMs as my 94GT did.
Hi Tres; Another person removed the front bracket off the right muffler and used it as a rear brackets on the left (it's the same bracket). Then he had a shop fabricate hangars for the front of both mufflers. That way he was able to get the mufflers to hang right without having to buy the left side brackets. Not a bad idea if you want to save 70 bucks! Who's sunroof do you have on yours? It looks nice!
I'm the one that did this, and it looks and sounds great with the right placement of the mufflers.
I just put my passenger GT muffler on and I'm waiting for my brackets for the driver's side from Clevenger Ford. They were actually $39.00 and some change apiece and not $35.00, but that still better than the $58.00+ apiece that the local Ford dealer wanted. I ordered bolts as well. BTW not much difference inside the car with the single GT muffler but it is a little rowdier outside the car. When I get the brackets I will get the driver's side relief cut and mount the muffler. I will then take the muffler off and have the muffler shop set me up with a true dual system with H-pipe.They said that it would be about $100.00 for the work. The H-pipe should improve torque. Thanks for the inspirational thread Tres!
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HOW TO: V6 dual GT mufflers w/ pics - 
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