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30400-03, 30405: Installation Instructions for Mustang Cat Back 2-1/2" Exhaust System with Turbo Mufflers

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Greg Gjerdingen

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Installation Instructions for 555-30400 Mustang Cat Back 2-1/2” Exhaust System with Turbo Mufflers

Application: 1987-1993 Ford Mustang 5.0L both GT and LX models

Note: contains turndowns tips to clear GT ground effects—can also be used on LX.

Kit Include:

2) rear 2-1/2” hanger clamps #2925

1) left extension pipe

2) front 2-1/2” hanger clamps #2926

1) right extension pipe

2) #SF67008 2 bolt 2-1/2” flanges

1) left tail pipe

4) 3/8” x 2-1/2” bolts

1) right tail pipe

2) 2-1/2” clamps

2) turbo muffler offset/offset 2-1/2” #920

4) 3/8” nuts

2) turndown tips

4) 3/8” lock washers

8) fender washers

DANGER WARNING: Should the purchaser decide to install this exhaust product at home, be warned that pleasure car or light duty truck/van “bumper” jacks are intended for emergency use only. The use of frame contact jack stands in conjunction with a floor jack as main support is highly recommended to minimize accidental dropping of a vehicle while the installation proceeds. We recommend the use of a shop hoist if possible. Please use caution!

Limitation of Liability–Disclaimers: The regulation of emissions production, noise levels and safety standards is undertaken by the federal government, each of the fifty state legislatures, and by many local municipalities, towns and counties.The manufacturer makes no warranties of merchantability, of fitness for a particular purpose, or that its products are approved for general use, or that its products comply with laws, regulations or ordinances in the states where they may be sold to the ultimate purchaser, the consumer.The entire risk as to the conformity of this product in any such state and as to repair, should the product prove to be defective or non-conforming, is on the retail purchaser, the buyer, the ultimate consumer of such product and it is not upon the seller, distributor, or manufacturer.In this connection, retail purchaser, the buyer, the ultimate consumer assumes the burden of the entire cost of any and all necessary service, alterations, and or repair.The foregoing statement limits the liability of the manufacturer.

NOTE: DO NOT TIGHTEN ANY BOLTS OR CLAMPS UNTIL THE LAST STEP!

1. Support the vehicle using either a shop hoist or with frame supports. The rear axle will need to hang free to allow clearance for the removal and installation of the pipes. Remove the old exhaust system behind the converter/h-pipe, where the old system bolts to the converter/h-pipe.

2. Install the left extension pipe (shortest pipe) to the converter/h-pipe, and slide a #SF67008 flange over the pipe. Connect the old converter flange to the new flange using a 3/8” x 2-1/2” bolt, lock washer ,nut, and two fender washers for each side of the flange. Tighten the assembly slightly, but do not over tighten at this time. It may be necessary to pivot both extension pipes to gain proper clearance of the muffler and tail pipe.

3. Install the right extension pipe (longer pipe) and repeat step 2) for the right side.

4. Install the mufflers to the extension pipes using 2-1/2” clamps on the front. Do not tighten at this time.NOTE: The mufflers are reversible.

5. Install the left tail pipe to the muffler using a front hanger clamp in the O.E. rubber hanger mount. Attach the clamp portion of the hanger to the connecting point of the tail pipe and muffler outlet. NOTE: on the left side only you may need to take a pliers and fold back a part of the gas tank (the corner) for clearance of the tail pipe if you prefer or if necessary.

6. Repeat step 5) for the right side.

7. Install a rear hanger clamp to the left tail pipe and connect to the O.E. rubber hanger mount.

8. Repeat step 7) for the right tail pipe.

9. For those with GT models, you will need to trim the tail pipes to length and install the turndown tips.Measure the required length to cut off, cut, and then install the turndowns to the tail pipes using the 2-1/2” rear hanger clamps to fasten.

10. Check for clearance of the frame and body, and of all brake and fuel lines. When you are satisfied with how the system hangs, tighten all bolts and clamps.

Installation Instructions for 555-30401Mustang Cat Back 3” Exhaust System with Turbo Mufflers

Application: 1987-1993 Ford Mustang 5.0L both GT and LX models.

Note: contains turndowns tips to clear GT ground effects—can also be used on LX

Kit Includes:

8) fender washers

1) left extension pipe w/flange

2) 3” hanger clamps #2924

1) right extension pipe w/flange

4) 3/8” lock washers

1) left tail pipe w/hanger

4) 3/8” x 2-1/2” bolts

1) right tail pipe w/hanger

4) 3” clamps

2) turbo muffler offset/offset 3” #921

4) 3/8” nuts

2) turndown tips

DANGER WARNING: Should the purchaser decide to install this exhaust product at home, be warned that pleasure car or light duty truck/van “bumper” jacks are intended for emergency use only. The use of frame contact jack stands in conjunction with a floor jack as main support is highly recommended to minimize accidental dropping of a vehicle while the installation proceeds. We recommend the use of a shop hoist if possible. Please use caution!

Limitation of Liability–Disclaimers: The regulation of emissions production, noise levels and safety standards is undertaken by the federal government, each of the fifty state legislatures, and by many local municipalities, towns and counties.The manufacturer makes no warranties of merchantability, of fitness for a particular purpose, or that its products are approved for general use, or that its products comply with laws, regulations or ordinances in the states where they may be sold to the ultimate purchaser, the consumer.The entire risk as to the conformity of this product in any such state and as to repair, should the product prove to be defective or non-conforming, is on the retail purchaser, the buyer, the ultimate consumer of such product and it is not upon the seller, distributor, or manufacturer.In this connection, retail purchaser, the buyer, the ultimate consumer assumes the burden of the entire cost of any and all necessary service, alterations, and or repair. The foregoing statement limits the liability of the manufacturer.

NOTE: DO NOT TIGHTEN ANY BOLTS OR CLAMPS UNTIL THE LAST STEP!

1. Support the vehicle using either a shop hoist or with frame supports. The rear axle will need to hang free to allow clearance for the removal and installation of the pipes. Remove the old exhaust system behind the converter/h-pipe, where the old system bolts to the converter/h-pipe.

2. Install the left extension pipe (shortest pipe) to the converter/h-pipe, and slide a #SF67008 flange over the pipe. Connect the old converter flange to the new flange using a 3/8” x 2-1/2” bolt, lock washer ,nut, and two fender washers for each side of the flange. Tighten the assembly slightly, but do not over tighten at this time. It may be necessary to pivot both extension pipes to gain proper clearance of the muffler and tail pipe.

3. Install the right extension pipe (longer pipe) and repeat step 2) for the right side.

4. Install the mufflers to the extension pipes using 2-1/2” clamps on the front. Do not tighten at this time.NOTE: The mufflers are reversible.

5. Install the left tail pipe to the muffler using a front hanger clamp in the O.E. rubber hanger mount. Attach the clamp portion of the hanger to the connecting point of the tail pipe and muffler outlet. NOTE: on the left side only you may need to take a pliers and fold back a part of the gas tank (the corner) for clearance of the tail pipe if you prefer or if necessary.

6. Repeat step 5) for the right side.

7. Install a rear hanger clamp to the left tail pipe and connect to the O.E. rubber hanger mount.

8. Repeat step 7) for the right tail pipe.

9. For those with GT models, you will need to trim the tail pipes to length and install the turndown tips.Measure the required length to cut off, cut, and then install the turndowns to the tail pipes using the 2-1/2” rear hanger clamps to fasten.

10. Check for clearance of the frame and body, and of all brake and fuel lines. When you are satisfied with how the system hangs, tighten all bolts and clamps.

Installation Instructions for 555-30402 Mustang Cat Back 2-1/2” Exhaust System with Turbo Mufflers

Application: 1994-1995 Ford Mustang 5.0L

Kit Includes:

2) rear 2-1/2” hanger clamps #2925

1) left extension pipe

2) front 2-1/2” hanger clamps #2926

1) right extension pipe

2) SF67008 2 bolt 2-1/2” flanges

1) left tail pipe

4) 3/8” x 2-1/2” bolts

1) right tail pipe

2) 2-1/2” clamps

2) #920 turbo muffler offset/offset 2-1/2”

4) 3/8” nuts4) 3/8” lock washers

8) fender washers

DANGER WARNING: Should the purchaser decide to install this exhaust product at home, be warned that pleasure car or light duty truck/van “bumper” jacks are intended for emergency use only. The use of frame contact jack stands in conjunction with a floor jack as main support is highly recommended to minimize accidental dropping of a vehicle while the installation proceeds. We recommend the use of a shop hoist if possible. Please use caution!

Limitation of Liability–Disclaimers: The regulation of emissions production, noise levels and safety standards is undertaken by the federal government, each of the fifty state legislatures, and by many local municipalities, towns and counties.The manufacturer makes no warranties of merchantability, of fitness for a particular purpose, or that its products are approved for general use, or that its products comply with laws, regulations or ordinances in the states where they may be sold to the ultimate purchaser, the consumer.The entire risk as to the conformity of this product in any such state and as to repair, should the product prove to be defective or non-conforming, is on the retail purchaser, the buyer, the ultimate consumer of such product and it is not upon the seller, distributor, or manufacturer.In this connection, retail purchaser, the buyer, the ultimate consumer assumes the burden of the entire cost of any and all necessary service, alterations, and or repair. The foregoing statement limits the liability of the manufacturer.

NOTE: DO NOT TIGHTEN ANY BOLTS OR CLAMPS UNTIL THE LAST STEP!

1. Support the vehicle using either a shop hoist or with frame supports. The rear axle will need to hang free to allow clearance for the removal and installation of the pipes. Remove the old exhaust system behind the converter/h-pipe, where the old system bolts to the converter/h-pipe.

2. Install the left extension pipe (shortest pipe) to the converter/h-pipe, and slide a #SF67008 flange over the pipe. Connect the old converter flange to the new flange using a 3/8” x 2-1/2” bolt, lock washer ,nut, and two fender washers for each side of the flange. Tighten the assembly slightly, but do not over tighten at this time. It may be necessary to pivot both extension pipes to gain proper clearance of the muffler and tail pipe.

3. Install the right extension pipe (longer pipe) and repeat step 2) for the right side.

4. Install the mufflers to the extension pipes using 2-1/2” clamps on the front. Do not tighten at this time.NOTE: The mufflers are reversible.

5. Install the left tail pipe to the muffler using a front hanger clamp in the O.E. rubber hanger mount. Attach the clamp portion of the hanger to the connecting point of the tail pipe and muffler outlet. NOTE: on the left side only you may need to take a pliers and fold back a part of the gas tank (the corner) for clearance of the tail pipe if you prefer or if necessary.

6. Repeat step 5) for the right side.

7. Install a rear hanger clamp to the left tail pipe and connect to the O.E. rubber hanger mount.

8. Repeat step 7) for the right tail pipe.

9. For those with GT models, you will need to trim the tail pipes to length and install the turndown tips.Measure the required length to cut off, cut, and then install the turndowns to the tail pipes using the 2-1/2” rear hanger clamps to fasten.

10. Check for clearance of the frame and body, and of all brake and fuel lines. When you are satisfied with how the system hangs, tighten all bolts and clamps.

Installation Instructions for 555-30403 Mustang Cat Back 2-1/2” Exhaust System with Turbo Mufflers

Application: 1999-2004 Ford Mustang 4.6L

Kit Includes

:2) rear 2-1/2” hanger clamps #2923

1) left extension pipe

2) front 2-1/2” hanger clamps #2926

1) right extension pipe

2) U250-2 (SF67008) 2 bolt 2-1/2” flanges

1) left tail pipe2) 2-1/2” clamps

1) right tail pipe

4) fender washers

2) #920 turbo muffler offset/offset 2-1/2”

DANGER WARNING: Should the purchaser decide to install this exhaust product at home, be warned that pleasure car or light duty truck/van “bumper” jacks are intended for emergency use only. The use of frame contact jack stands in conjunction with a floor jack as main support is highly recommended to minimize accidental dropping of a vehicle while the installation proceeds. We recommend the use of a shop hoist if possible. Please use caution!

Limitation of Liability–Disclaimers: The regulation of emissions production, noise levels and safety standards is undertaken by the federal government, each of the fifty state legislatures, and by many local municipalities, towns and counties.The manufacturer makes no warranties of merchantability, of fitness for a particular purpose, or that its products are approved for general use, or that its products comply with laws, regulations or ordinances in the states where they may be sold to the ultimate purchaser, the consumer.The entire risk as to the conformity of this product in any such state and as to repair, should the product prove to be defective or non-conforming, is on the retail purchaser, the buyer, the ultimate consumer of such product and it is not upon the seller, distributor, or manufacturer.In this connection, retail purchaser, the buyer, the ultimate consumer assumes the burden of the entire cost of any and all necessary service, alterations, and or repair. The foregoing statement limits the liability of the manufacturer.

NOTE: DO NOT TIGHTEN ANY BOLTS OR CLAMPS UNTIL THE LAST STEP!

1. Support the vehicle using either a shop hoist or with frame supports. The rear axle will need to hang free to allow clearance for the removal and installation of the pipes. Remove the old exhaust system behind the converter/h-pipe, where the old system bolts to the converter/h-pipe.

2. Install the left extension pipe (shortest pipe) to the converter/h-pipe, and slide a #SF67008 flange over the pipe. Connect the old converter flange to the new flange using a 3/8” x 2-1/2” bolt, lock washer ,nut, and two fender washers for each side of the flange. Tighten the assembly slightly, but do not over tighten at this time. It may be necessary to pivot both extension pipes to gain proper clearance of the muffler and tail pipe.

3. Install the right extension pipe (longer pipe) and repeat step 2) for the right side.

4. Install the mufflers to the extension pipes using 2-1/2” clamps on the front. Do not tighten at this time.NOTE: The mufflers are reversible.

5. Install the left tail pipe to the muffler using a front hanger clamp in the O.E. rubber hanger mount. Attach the clamp portion of the hanger to the connecting point of the tail pipe and muffler outlet. NOTE: on the left side only you may need to take a pliers and fold back a part of the gas tank (the corner) for clearance of the tail pipe if you prefer or if necessary.

6. Repeat step 5) for the right side.

7. Install a rear hanger clamp to the left tail pipe and connect to the O.E. rubber hanger mount.

8. Repeat step 7) for the right tail pipe.

9. For those with GT models, you will need to trim the tail pipes to length and install the turndown tips.Measure the required length to cut off, cut, and then install the turndowns to the tail pipes using the 2-1/2” rear hanger clamps to fasten.

10. Check for clearance of the frame and body, and of all brake and fuel lines. When you are satisfied with how the system hangs, tighten all bolts and clamps.

Installation Instructions for 555-30405 Mustang Cat Back 2-1/2” Exhaust System with Turbo Mufflers

Application: 1996-1997 Ford Mustang 4.6L GT

Kit Includes:

2) rear 2-1/2” hanger clamps-#2926

1) left extension pipe

1) left front 2-1/2” hanger clamps-#2867

1) right extension pipe

1) right front 2-1/2” hanger clamps-#2866

1) left front tail pipe

8) fender washers

1) right front tail pipe

4) 2-1/2” clamps

2) #920 turbo muffler offset/offset 2-1/2”

2) SF67008 2 bolt 2-1/2” flanges

1) left rear tail pipe

1) right rear tail pipe

DANGER WARNING: Should the purchaser decide to install this exhaust product at home, be warned that pleasure car or light duty truck/van “bumper” jacks are intended for emergency use only. The use of frame contact jack stands in conjunction with a floor jack as main support is highly recommended to minimize accidental dropping of a vehicle while the installation proceeds. We recommend the use of a shop hoist if possible. Please use caution!

Limitation of Liability–Disclaimers: The regulation of emissions production, noise levels and safety standards is undertaken by the federal government, each of the fifty state legislatures, and by many local municipalities, towns and counties.The manufacturer makes no warranties of merchantability, of fitness for a particular purpose, or that its products are approved for general use, or that its products comply with laws, regulations or ordinances in the states where they may be sold to the ultimate purchaser, the consumer.The entire risk as to the conformity of this product in any such state and as to repair, should the product prove to be defective or non-conforming, is on the retail purchaser, the buyer, the ultimate consumer of such product and it is not upon the seller, distributor, or manufacturer.In this connection, retail purchaser, the buyer, the ultimate consumer assumes the burden of the entire cost of any and all necessary service, alterations, and or repair. The foregoing statement limits the liability of the manufacturer.

NOTE: DO NOT TIGHTEN ANY BOLTS OR CLAMPS UNTIL THE LAST STEP!

1. Support the vehicle in a safe manner, using a shop hoist or frame contact jack stands on a level surface. Remove the old exhaust system behind the converter/h-pipe, where the old system bolts to the converter/h-pipe. You will need to cut the original exhaust system in pieces to remove it from the vehicle. Use a lubricant or heat the nuts for easier removal (you need to re-use the original studs and nuts at the flanges.

2. Install the left extension pipe (shortest pipe) to the converter/h-pipe, and slide a SF67008 flange over the pipe. Connect the old converter flange to the new flange using the original studs and nuts for each side of the flange. Tighten the assembly slightly, but do not over tighten at this time. It maybe necessary to pivot both extension pipes to gain proper clearance of the muffler and tail pipe.

3. Install the right extension pipe (longer pipe) and repeat step 2) for the right side.

4. Install the mufflers to the extension pipes using 2-1/2” clamps on the front. Do not tighten at this time. NOTE: The mufflers are reversible.

5. Install the left front tail pipe to the muffler using the left front hanger clamp in the O.E. rubber hanger mount (it is the longer of the two front hanger clamps—see illustration). Attach the clamp portion of the hanger to the connecting point of the tail pipe and muffler outlet.

6. Install the left rear tail pipe to the left front tail pipe using a 2-1/2” clamp.

7. Repeat step 5) for the right side, using the right front hanger clamp (shorter hanger).

8. Repeat step 6) for the right side.

9. Install a rear hanger clamp to the left rear tail pipe and connect to the O.E. rubber hanger mount.

10. Repeat step 9) for the right tail pipe.

11. Trim your tail pipes to your desired length and style of cut, if you prefer.

12. Check for clearance of the frame, body, suspension members, and of all brake and fuel lines. When you are satisfied with how the system hangs, tighten all bolts and clamps.

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Posted on
May 10, 2018
in
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