The Bassani V-6 dual exhaust...
The Bassani V-6 dual exhaust kit is a great solution for those wanting the look of dual tailpipes, a deeper exhaust note, and simple installation. All told, our install took about two hours using hand tools and a lift. Figure three hours for DIY installation on your back in the driveway.
Tech | Dual Exhaust Upgrade
Let's face it; there are a dozen reasons why you might buy a V-6 powered late-model Mustang. From fuel economy and low initial price, to cheaper insurance and lighter weight, we've heard them all. With all the horsepower in our own garage already we could easily see a V-6 Mustang as an option for a nice daily driver while still waving the blue oval flag. But that doesn't mean you still can't personalize your V-6 ride with a little more power, better braking, some good looks, and what not. It's not hard to do either, as many of the bolt-on goodies in the looks department are the same for the GT as the V-6 (billet knobs, and such). The aftermarket companies strewn throughout this magazine also realize that the majority of Mustang sales are indeed V-6 models, so if they want to capitalize on Ford's sales figures they opt to make V-6 specific parts as well (cold air induction kits, power programmers, and more).
The one area we've not seen a whole lot of offerings for has been V-6 exhaust systems. Many companies opt for the direct replacement single exhaust kit with varying degrees of success in making it look good and sound good. The last thing we like hearing is buzz-bomb import exhaust sound coming from a Mustang, and we're pretty sure you feel the same way too, which is why many V-6 owners opt to not even touch their exhaust system.
Another "gotcha" to the whole V-6 exhaust upgrade is the rear valance. Usually running dual exhaust on a '94-'04 Mustang means pointing the tips downward or having them lower than the stock location to point straight out the rear. For the '05 and up Mustang owner the problem becomes the stock single exhaust cutout in the rear fascia. Do you put on a GT rear fascia at considerable expense (don't forget you'll most likely have to get it painted), or do you trim the driver side to match?
Begin by removing the factory...
Begin by removing the factory single exhaust muffler assembly on the passenger side of the car. The Bassani instructions state to unbolt the muffler hangers from the body and remove with the muffler, which we did here.
The folks at Bassani have your V-6 exhaust answer under three different part numbers. The basic kit, PN 40055, is its single exhaust axle-back performance muffler kit, which you can find for about $285. The kit we're using, PN 40755, is the Aft-Cat system that splits the single exhaust into duals at the rear axle area and then uses two regular Bassani Mustang GT mufflers. We found this kit for $575. Finally, the company also offers PN 40765, which is its Aft-Cat with X-crossover that essentially converts the V-6 Mustang to true dual exhaust, which will run you about $700. So, three options, three price points, and three solutions to your V-6 Mustang exhaust upgrade from Bassani; all in full stainless steel we might add. See the photos for the basic nut and bolt action and be sure to check out our website at www.mustangandfords.com for video of the installed system.
After you have all of the...
After you have all of the exhaust hangers unbolted from the car you can loosen the factory slip clamp that retains the muffler to the mid-pipe just behind the rear axle.
The mid-pipe will need to...
The mid-pipe will need to be cut back to fit the Bassani-supplied Y-pipe assembly to convert the single exhaust to duals after the axle housing.
The instructions call for...
The instructions call for cutting the mid-pipe 21/2-inches after the upward bend in front of the rear axle. We used a multi-angle Craftsman reciprocating saw to get into the tight space we needed to make the cut in the right place. Don't worry if the cut isn't 100 percent straight, as the slip fit of the Y-pipe will cover it. If you need to, you can remove the mid-pipe (there's a slip clamp farther forward under the car) to get to the cutting spot.
Once you've completed the...
Once you've completed the cut, remove the aft section of the mid-pipe and introduce it to the nearest garbage can.
In this photo you can see...
In this photo you can see the freshly cut mid-pipe's outlet. One thing to note here is the pipe's penchant to lean toward the passenger side. Later, after completing the install we found the system lined up better after loosening the aforementioned slip clamp forward of the cut and slightly rotating the new outlet to the left a bit.
There's a fuel vapor vent...
There's a fuel vapor vent tube that needs to be carefully modified to clear the new Y-pipe tubing. The Bassani kit includes a brass fitting that you install into the cut vent tube, allowing you to rotate the outlet of the vent to best clear the installed exhaust system.
Now that the stock exhaust...
Now that the stock exhaust system has been prepped you can move forward with installing the first part of the new Bassani system; the Y-pipe assembly. Slip a 21/2-inch clamp over the inlet of the Y-pipe and then slide the Y-pipe over the modified mid-pipe. Snug the clamp up with a ratchet, but don't make it too tight you can't adjust the Y-pipe.
Next you'll install the right-side...
Next you'll install the right-side intermediate pipe to the Y-pipe. Again, first install a 21/4-inch clamp on the end, slip it on the Y-pipe, and then add another 21/4-inch clamp to be tightened later for the muffler. Snug the clamp at the Y-pipe to hold the intermediate pipe in place.
The left-side crossover pipe...
The left-side crossover pipe requires a little finesse to get around the axle housing and suspension, but once you've snaked it through all of that you'll see how it should route. Again, place a 21/4-inch clamp on each end and snug the clamp at the Y-pipe end for now.
Transfer the original passenger-side...
Transfer the original passenger-side muffler hangers to the new Bassani right side muffler and install the muffler. Tighten the brackets completely, but leave the pipe clamp loose for now
On the driver side you'll...
On the driver side you'll need to tap four existing holes with a 5/16-18 tap. These holes are identified by their thick inserts and not just a hole in the sheetmetal. These threaded holes will take the retaining bolts for the Bassani-supplied muffler hangers.
Temporarily mount the driver-side...
Temporarily mount the driver-side muffler using the Bassani-supplied hangers. You'll need to do this to locate the muffler outlet against the rear fascia so that the fascia can be trimmed.
The instructions include a...
The instructions include a 1:1 scale paper template for the tailpipe tip opening on the driver side of the fascia. Be smart and make an extra copy or two before cutting the template out just in case you ruin the template during mock up.
To cut the soft fascia material,...
To cut the soft fascia material, a rotary file bit is probably your best bet. We chucked one up in our trusty Craftsman rotary tool and slowly followed the scribe line we made from the paper template.
Once the fascia has been modified...
Once the fascia has been modified you can reinstall the left-side muffler and Bassani-supplied hangers for the last time.
While the plastic fascia won't...
While the plastic fascia won't rust, you should take the extra step to touch up the opening with some body color paint for that professional looking result.
Here's another shot of the...
Here's another shot of the finished muffler install. Note the outlet and its location to the new fascia opening. Take your time and slowly work your way from the Y-pipe out to both mufflers, aligning the system and tightening all of the clamps to ensure a rattle-free fit.
The included 4-inch double-wall...
The included 4-inch double-wall polished tips are works of art and really set the Bassani system off nicely. Even better, the tips are installed separately of the muffler casing using stainless band clamps, allowing easy depth adjustment for just the look you want from your dual exhaust.
Every Bassani system comes...
Every Bassani system comes with the famous Bassani tribal flame skull logo decal; wear it with pride!
The finished installation...
The finished installation looks great (we did go back and trim the fascia a bit more after final system alignment) and it sounds awesome too. Don't forget to go online and listen to the system via the video section of our website.