When Ford was burning the midnight oil developing the all-new S197 generation of Mustangs for 2005, it was the first time that Ford intentionally developed a Mustang with the complete involvement of the aftermarket industry. Ford engineers and product planners worked hand-in-hand with aftermarket companies to develop an enthusiast-friendly Mustang. Based on five years of experience with these cars, we can testify they're the easiest late-model Mustang we've ever worked with.
Case in point is the S197's exhaust system. Prior to '05, exhaust system modifications involved a Sawzall, a pipe bender, and a welder. Beginning with the '05 model year, Mustang exhaust systems became bolt-on-from catalytic converters to tailpipe. Instead of tucking mufflers just ahead of the rear axle, Ford moved them behind the rear bumper with easy-to-service couplings and insulated hangers, which has made exhaust system modifications something you can do on your garage floor.
Dynomax Performance Exhaust offers Mustang enthusiasts a huge array of exhaust system options for classic and late-model Mustangs alike. The new Dynomax Ultra-Flo exhaust system for '05-'10 Mustangs is a cat-back system with subway-sized 2 1/2- and 3-inch diameter pipes. This performance exhaust will take your three-valve Modular V-8 and give it a muscular voice without making you deaf in the cabin. These stainless steel systems are available for all '05-'10 Mustangs, including GT, Shelby GT, Shelby GT500, and V-6 models. There are two ways to purchase these systems-cat-back or H-pipe back. We're going to install the H-pipe back system with 3-inch pipes and bullet mufflers on an '07 California Special.
Here's the complete Dynomax...
Here's the complete Dynomax Ultra-Flo stainless steel exhaust system, including a crossover pipe for maximum performance. This is what we suggest for owners who want a crackly roar along with an improvement in horsepower. Dynomax's dyno testing has shown an improvement of 21 horsepower along with a corresponding increase of 18 ft-lb of torque.
This is the system we're installing...
This is the system we're installing on our '07 California Special, the 3-inch Ultra-Flo bullet muffler system with 3 1/2-inch tips for Shelby GT and GT500.
Marlon Mitchell of Fly-Ford...
Marlon Mitchell of Fly-Ford Racing is impressed with the Dynomax bullet muffler. It delivers a sharp, crackly roar when the throttle is goosed without being offensive inside the cabin. Huge 3 1/2-inch pipes segue into bullet mufflers with 3 1/2-inch tips.
The stock Ford mufflers are...
The stock Ford mufflers are disconnected at the exhaust pipes. Quick-disconnect clamps, like the ones used in aircraft pneumatic systems, make this job easy.
Each muffler has two hangers-one...
Each muffler has two hangers-one fore and aft. The trick is removing these hangers and remembering where each went.
Because these hangers are...
Because these hangers are identical in appearance, yet different, it's easy to get them backwards. Take note of proper positioning during removal. Much of it has to be done by feel because the hangers are not always visible.
Once the hangers are disconnected,...
Once the hangers are disconnected, the mufflers drop right out of their pockets. It is amazing how easy this is when you consider muffler replacement on '65-'04 Mustangs.
As mentioned previously, it's...
As mentioned previously, it's easy to get the muffler hangers mixed up and wind up with mufflers that won't hang correctly. Take digital pictures when mufflers are removed so you can keep the hangers in their original locations when transferring them to the new mufflers.
Marlon Mitchell disconnects...
Marlon Mitchell disconnects both the exhaust pipes between the H-pipe and mufflers. This is as easy as muffler removal.
The new Dynomax 3-inch pipes...
The new Dynomax 3-inch pipes are installed next. All Marlon has to do is plug them into the existing H-pipe and tighten the clamps.
Installed, our 3-inch pipes...
Installed, our 3-inch pipes look huge. Clamps have been tightened and we're ready for mufflers.
Dynomax bullet mufflers get...
Dynomax bullet mufflers get new clamps thanks to the hefty 3-inch sewer pipes. These clamps work the same way as the factory pieces to provide solid security without the hassle of a saw and welder.
Hangers are installed on our...
Hangers are installed on our Dynomax bullet mufflers just like they were located on the factory mufflers, which is why we suggest paying close attention to the original locations.
The Dynomax mufflers are installed...
The Dynomax mufflers are installed as shown, then clamped to the pipes. Carefully check muffler positioning, getting the tips uniform on each side. Where it gets challenging is muffler positioning. When hangers are welded at the factory, they move as they cool, which alters hanger position during contraction.
Sometimes, you have to heat...
Sometimes, you have to heat and bend the Dynomax hangers to get muffler positioning just right. This is typical of most aftermarket mufflers for late-model Mustangs.
| Dynomax Ultra Flo Exhaust Systems |
| #39414 | Dual 2 1/2-inch pipes, mufflers with 3 1/2-inch tip '05-'09 Mustang GT, Shelby GT, Shelby GT500 |
| #39434 | Dual 2 1/2-inch pipes, mufflers with 3 1/2-inch tips '05-'09 Mustang 4.0L V-6 |
| #39460 | Dual 3-inch pipes, bullet mufflers with 3 1/2-inch tip '05-'09 Shelby GT, Shelby GT500 |
New Ultra-Flo systems are available for '10 Mustang, with an '11 version coming soon. Go to www.dynomax.com for more detail.