It’s a time-honored tradition for late-model Mustangs. Upgrading to a performance exhaust system not only improves horsepower, it also adds that Mustang-specific exhaust tone that has been so popular since the first 5.0s of the mid 1980s. Now that the SN-95 Mustangs of ’94-’04 are becoming more affordable as used cars, owners are upgrading to a performance exhaust either as a replacement for an aging original system or to replace a previous owner’s attempt with a mismatched hodge-podge of headers, H-pipe (or crossover pipe), mufflers, and tailpipes.
That was the case with Joe Galloway’s ’98 Mustang, an original V-6 coupe with a transplanted 4.6-liter V-8 powertrain. It still had the original 4.6 exhaust manifolds and H-pipe, but the cat-back duals were a left-over from the car’s V-6 days. The system hung too low, causing conflicts with speed bumps, and it was just too loud with the V-8. A new performance exhaust system from front to back would alleviate all of the problems, not to mention adding power with long-tube headers and high-flow catalytic converters.
For his new exhaust, Joe ordered a set of chrome long-tube headers (part number 1541) and catalytic H-pipe (1538) from BBK Performance. Shorter than the factory H-pipe, the BBK version adapts perfectly to the long-tube headers and clears the ’94-’98 double-hump transmission crossmember (later ’99-’04 Mustangs use a smaller crossmember, so make sure the headers are designed for the earlier version). At the rear, a MagnaFlow cat-back system (part number 15638) features stainless steel construction for long-lasting durability and a smooth, deep exhaust tone that doesn’t drown out interior conversations with unwanted drone.
For technical expertise, we headed to Lamotta Performance in Orlando, Florida, where Jake Lamotta has been modifying and tuning late-model Mustangs since the hey-day of 5.0 Mustangs in the 1980s. Jake has installed many a performance exhaust, so we knew we could depend on him and his crew for an expert installation.
MagnaFlow’s cat-back exhaust...
MagnaFlow’s cat-back exhaust system for ’94-’98 Mustangs and Cobras comes with a pair of stainless steel performance mufflers, extension pipes, tailpipes, chrome tips, and all installation hardware, including hangers and band clamps.
Our long-tube headers from...
Our long-tube headers from BBK Performance came in chrome with 1-5⁄8-inch tubes and 3⁄8-inch laser-cut flanges. They are a big improvement over the factory cast-iron exhaust manifolds. BBK also offers these headers with a ceramic coating.
With long-tubes headers, a...
With long-tubes headers, a standard catalytic-converter H-pipe assembly is too long. BBK offers a mid-length H-pipe, with high-flow converters, specifically for use with their long-tube headers. They are not legal for California.
Jake Lamotta from Orlando’s...
Jake Lamotta from Orlando’s Lamotta Performance gets started by removing the existing H-pipe and cat-back mufflers. There are two nuts at each exhaust manifold and rear connection. You may need some penetrating oil to loosen stubborn nuts from the studs. The car-back system was also unbolted and removed.
Most of the exhaust manifold...
Most of the exhaust manifold bolts can be reached from underneath, as shown here by Lamotta Performance’s Matthew Gagliardi. Our ’98 Mustang is equipped with a tubular K-member, so access is easier than with the larger factory unit. Starter removal also helps with access.
Jake prefers to begin the...
Jake prefers to begin the exhaust system installation at the rear with the MagnaFlow cat-backs. MagnaFlow supplies ’99-up hangers for the ’94-’98 mufflers and tailpipes so they are installed first.
The rear cat-back installation...
The rear cat-back installation begins by sliding the tailpipes over the rear axle housing. They can hang there while the tips are installed.
The 3½-inch chrome tips install...
The 3½-inch chrome tips install over the tailpipes. Once everything is bolted up and adjusted, they will be secured with band clamps.
Each tip mounts to the factory...
Each tip mounts to the factory hangers with a long, adjustable rod.
The front of the each tailpipe...
The front of the each tailpipe mounts to the provided ’99-’04 hangers, which are dual purpose, with an outside hanger for the front of the tailpipe and an inner hanger for the muffler.
Slip the MagnaFlow mufflers...
Slip the MagnaFlow mufflers into the tailpipes, then hang from the inner portion of the hanger. Slide the band clamp over the connection and tighten just enough to hold everything in place. You’ll want to wait until the system is properly adjusted before tightening down the clamps.
The BBK headers slide in place...
The BBK headers slide in place from underneath, aided by the tubular K-member in our case. It’s a little trickier with the bulky factory K-member. As with the removal of the factory exhaust manifolds, most of the header bolts can be installed and tightened from underneath the car, although a couple can only be reached from the top.
Transfer the oxygen sensors...
Transfer the oxygen sensors from the factory H-pipe to the BBK H-pipe.
With the headers installed,...
With the headers installed, the H-pipe can be positioned. Install the nuts to hold in place but do not tighten.
Install the pair of extension...
Install the pair of extension pipes that connect the H-pipe to the mufflers. Secure with the band clamps but do not tighten completely.
Now comes the tedious part...
Now comes the tedious part of adjusting the exhaust system. You want to make sure the exhaust tips are uniform and do not touch the rear valance. Also, the H-pipe shouldn’t droop or contact the transmission crossmember.
Once the exhaust system is...
Once the exhaust system is adjusted properly, tighten all of the band clamps. You can also weld the connection for extra security.
Here’s a look at Joe’s new...
Here’s a look at Joe’s new exhaust system, which not only looks great, it also sounds great.