Installing a performance exhaust system of some sort has been a long, time-honored tradition in the late-model side of the Mustang hobby. For both Fox and SN-95 5.0s and 4.6s, a plethora of aftermarket systems are available.
A quick review is in order to see how to install a basic system that replaces the stock setup from behind the catalytic converters to the tailpipe. What does it take? Not much when you're talking about fitting a Bassani after-cat system such as the one we installed on a supercharged '95 GT owned by Dave Deis.
There's a simple reason for the ease with which a Bassani system is put on a Mustang: quality. We stopped in at DB Performance Engineering, a shop we've known about for several years that works on both late-model and vintage Mustang iron, and Danny Banh had the Bassani system on the car in less than two hours.
Two tailpipes and two mufflers-Bassani's...
Two tailpipes and two mufflers-Bassani's after-cat exhaust system is as simple as can be. Installation hardware is included to attach it to the H-pipe, as well as a pair of clamps to join the mufflers and tailpipes in front of the rear axle. The rest of the system installs using all the car's existing hangers. This system for '94-'95 5.0s carries PN 50945S. Because hangers for the tailpipes are oriented differently, there are two basic systems for pre-'99 SN-95s and the current '99-'03 car.
Even better, Danny's shop is a distributor for Bassani equipment, so it's truly a one-stop affair to get a Bassani system on your car in the SoCal area. There are several applications of Bassani systems for late-model 5.0s and 4.6s, as well as different setups for '94-'98 round-body SN-95s and '99-'04 square-edge cars due to the unique rear fascias of the two body styles.
Installation highlights and details on SN-95 applications follow. You can also visit Bassani's Web site (www.bassani.com) for specific details on part numbers and applications for other Mustangs.
Begin removing the stock system...
Begin removing the stock system by loosening the hangers that hold the system in place right behind the mufflers.
Loosen and remove the four...
Loosen and remove the four bolts that hold the mufflers in place to the H-pipe.
If things are tight, a light...
If things are tight, a light tap on the muffler mounting flange with a plastic hammer helps separate the mufflers and the H-pipe.
Next, the tailpipes are removed...
Next, the tailpipes are removed from their hangers by prying them off; a large screwdriver or crowbar does the trick.
Note the difference in the...
Note the difference in the way the mounting tabs are oriented on the tailpipe. The pipe being removed is on our '95 GT subject car, while the other car is an '01 GT. That's why Bassani offers different systems.
If the rubber in the tailpipe...
If the rubber in the tailpipe hangers is dried out, a spray lubricant like WD-40 is a big help in getting the tailpipe separated from the hanger.
You have a couple of choices...
You have a couple of choices here. To remove the stock system, you need to cut the pipe directly behind the muffler. If you want to avoid cutting the stock system, drop the rear axle to get the tailpipes out-something you might want to do if you have, say, a collectible late-model like a Cobra, a Bullitt, or a Mach 1 and don't want to weld the stock system back together if you decide to reinstall it in the future.
Once the tailpipes and mufflers...
Once the tailpipes and mufflers are separated, the tailpipes come right out from behind the car, provided the car is on the type of hoist from which the rear axle can hang. If you have the car on a ramp-style hoist, it might take more effort to get the tailpipes free. In any case, having the axle hang down (with the weight of the car off of it) helps, since it provides additional clearance between the car and rearend.
The Bassani system uses all...
The Bassani system uses all stock hangers. The ones that hold the mufflers in place slide right onto the muffler hangers, as shown.
The Bassani tailpipes slip...
The Bassani tailpipes slip over the rear axle and connect to the existing hangers underneath the rear bumper cover.
Once the tailpipe is in place,...
Once the tailpipe is in place, the next step is to install the mufflers. Slip the muffler into the tailpipe, as shown, and be sure to have the clamp already in place before joining the muffler and tailpipe.
When putting the muffler and...
When putting the muffler and tailpipe together, it helps to have two people hold everything, while the person underneath the car tightens the muffler clamps and the other installs the tailpipe on the rear hanger.
Final-tighten the hangers...
Final-tighten the hangers behind the mufflers, as shown.
Next, tighten the muffler...
Next, tighten the muffler clamps.
Final-tighten the mufflers...
Final-tighten the mufflers to the H-pipe.
Proper alignment with the...
Proper alignment with the Bassani system requires little worry. Once everything is bolted down, alignment-in the case of this car-is right on the money. The big rear tips look good, too. To see underneath, refer to the photo at the beginning.
A unique feature of the Bassani...
A unique feature of the Bassani system is removable baffles. Removing them is as easy as unbolting the Allen screw and pulling the baffle out of the pipe.
The baffles come installed...
The baffles come installed in the pipes and are removed in a few seconds. Without the baffles, the Bassani exhaust noise is about the same as other aftermarket systems. Count on the Bassani system being about 2-3 dB quieter with the baffles.