How to Install Stainless Works Turbo Chambered Cat-Back Exhaust w/ Off-Road X-Pipe (03-04 Cobra w/ Long Tube Headers) on your Ford Mustang

Thanks for purchasing Stainless Works 3” Muscleflow exhaust for your Cobra.  We have gone to great pains to make sure that our exhaust systems fit and sound great.  Please follow these steps to ensure that your installation goes as planned.   
 
1. Installing the 3” exhaust is best performed on a lift by a qualified technician.  Make sure that the vehicle is well supported before working underneath.  Remove the factory exhaust system and remove the factory O2 sensors.  Note that the factory O2 sensor connections are color-coded and need to be reinstalled as removed.

2. The system includes the following:  2 head pipes, 2 catalytic converters (or off road pipes only if the system was ordered as an off road use only system), 2 off road pipes, 2 front intermediate pipes, x crossover, 2 rear intermediates, 2 mufflers, 2 front tailpipes, 2 rear tailpipes, 2 tips, 12 clamps.  All of the components are installed in this order.

3. Install the O2 sensors in the head pipes and front intermediates.  Use never seize on the threads but do not get any on the O2 sensor element.  Install head pipes using red high temp RTV on the oval flange in place of the factory gasket and red high temp RTV on the ball and socket joint on the other side.  Using the factory fasteners, snug head pipes to exhaust manifolds but do not fully tighten.  Install catalytic converters (or off road only pipes) onto headpipes.  Slip the two front intermediate pipes into the x-crossover, and then slide assembly onto catalytic converter outlets (or off road only pipes).  We recommend using high temp red RTV or muffler cement at all joints to prevent leaking, and also placing a small tack weld at each joint to secure the exhaust system once in place for extra security.  Do not tack weld or tighten clamps until the system is in place.

4. Install the rear intermediates into the x crossover, and then the mufflers onto the rear intermediates.  Next install the tailpipes and supplied tips.

5. Clamp the two supplied hangers to the top of the 3” extension that is welded to the exhaust tip.     

6. Make sure to have adequate clearance around all wires, hoses and lines.  If anything is in contact with the exhaust system, it will melt.  Make sure to have at least ½” of clearance and wrap any suspect areas with DEI thermal barrier wrap.   

7. After all pipes are lined up, tighten all clamps.  We do highly recommend placing a small tack weld at each joint for added security. 

8. After double-checking for clearance and making sure all lines, wires and hoses are secured, drive the car for 10-20 miles and re-check all clamps and clearances.