Oversquare
Well-Known Member
- Joined
- June 14, 2004
- Messages
- 191
- Reaction score
- 1
- City, State
- Wine Country
- Year, Model & Trim Level
- '00 XLT 5.0 AWD
2 weeks ago I installed a Flowmaster cat-back exhaust system. I bought it from Summit Racing for $235.69 (plus tax and shipping) part number FLO-17364.
I wanted an exhaust system that I could hear under accleration, but would not droan under highway speeds. I was looking to free up the restriction of the stock exhaust, but no loose any low-end torque.
http://www.explorerforum.com/forums/showthread.php?t=118026
I installed the system in my sloped driveway, in the dark, with no jack or lift, by myself. Yes, it can be done, but I would recommend better conditions, or at least some help. The installation is less difficult than changing spark plugs. If you're comfortable with that, then you should be able to do this.
The system came very well packaged, and with good instructions.
First I began by disconnecting the exhaust connections between the stock muffler and the catalytic converters. I then tried to remove the system with no luck. I finally broke down and read the instructions, only to find out the first necessary step is to cut the stock exhaust just after the muffler. Damn...
I cut the stock exhaust about 4" from the muffler with a Sawzall. The rear section came out with a little wiggling, twisting, and pulling. The muffler came out after this was removed.
HINT: When unbolting the clamp on one of the pipes from cat to muffler, use a small flat-blade screwdriver to pry the tabs off of the inner pipe (see pics below). This will release the pipe easier, and make things better.
After removing the stock system, I laid them out to compare the two. The most drastic difference isn't the pipe size (which isn't much bigger than stock) but the lack of kinks at the bends. The Flowmaster system has very smooth bends (mandrel bent) and seems to fit well. The Flowmaster system does not have the resonator. Something that shocked me is the SIZE of the Flowmaster muffler. This thing is HUGE! Much bigger than other Flowmaster mufflers I've delt with - and as heavy as the stock muffler. (See Pics Below)
Laying on my back, i supported the new muffler with my knees and guided it into place. Not an easy task, but doable. Once the slip fit over one front pipe, and the bolts in place for the other side, it stayed up well.
HINT: Don't over-tighten the 2 flange bolts next to the slip fit connection. They will bend the round flange and create an exhaust leak.
HINT: Remove the stickers on the rear pipe section before you install them. Otherwise they'll smell and cook off. I used an old razor blade to peel them off.
The rear clamp/mount is difficult. After sliding the new rear exhaust pipe through the truck and into the muffler, I had to tighten the clamp to hold the muffler in place, as well as hold the new pipe in the slip fit connection. The trick here was to push the muffler as far forward as possible, and pull the clamp as far rearward as possible - bringing the clap as close to the fitting as possible. (See pic for description)
HINT: The "washers" on the rear clamp, they're not washers. I crushed them thinking they were washers, but upon further inspection of the instructions, they were designed to prevent the exhaust from slipping of the rubber post mounts. Don't make the same mistake I did.
All bolted up and ready to go, right? Cool.
PROBLEM! Almost immediately after my test drive around the block, i noticed the rear pipe had rotated in it's slip-fit conneciton, allowing the tip to rest against the fender. This caused the fender to melt against the tip and make a mess. After re-tightening, clamping, re-tightening, fidgeting, and some more re-tightening, I finally got the rear exhaust pipe to stay in place without rotating and resting against the fender. This was VERY frustrating, and I would strongly recommend having the rear section welded to the muffler to prevent this.
My initial impressions were not good - as I couldn't get the pipe situated. Also, i felt the exhaust tone was too quiet and didn't notice a signifigant improvement in power. The exhaust tip seems a bit large (3.5"), but it's grown on me since I've installed it. I still might change it to a smaller size (3") in the future.
After a few weeks of driving, I'm much happier with the system. The pipe fitting issue seems to be fixed. The exhaust tone has 'loosened up' and become a little more noticeable, and it exactally where I would want it. I've noticed a power gain between 2000 and 4000 RPM at part throttle and WOT. I haven't noticed ANY loss of torque (good!). Unfortunately, I haven't experienced much of an increase in MPG - maybe about 1/2 mpg.
Overall, I would give the system a 7 out of 10. It had a fair price, is well constructed (except for the pipe fitting issue), and complete with good instructions (which I suggest you read).
-Brad
PS - can someone host and post pics for me?
I wanted an exhaust system that I could hear under accleration, but would not droan under highway speeds. I was looking to free up the restriction of the stock exhaust, but no loose any low-end torque.
http://www.explorerforum.com/forums/showthread.php?t=118026
I installed the system in my sloped driveway, in the dark, with no jack or lift, by myself. Yes, it can be done, but I would recommend better conditions, or at least some help. The installation is less difficult than changing spark plugs. If you're comfortable with that, then you should be able to do this.
The system came very well packaged, and with good instructions.
First I began by disconnecting the exhaust connections between the stock muffler and the catalytic converters. I then tried to remove the system with no luck. I finally broke down and read the instructions, only to find out the first necessary step is to cut the stock exhaust just after the muffler. Damn...
I cut the stock exhaust about 4" from the muffler with a Sawzall. The rear section came out with a little wiggling, twisting, and pulling. The muffler came out after this was removed.
HINT: When unbolting the clamp on one of the pipes from cat to muffler, use a small flat-blade screwdriver to pry the tabs off of the inner pipe (see pics below). This will release the pipe easier, and make things better.
After removing the stock system, I laid them out to compare the two. The most drastic difference isn't the pipe size (which isn't much bigger than stock) but the lack of kinks at the bends. The Flowmaster system has very smooth bends (mandrel bent) and seems to fit well. The Flowmaster system does not have the resonator. Something that shocked me is the SIZE of the Flowmaster muffler. This thing is HUGE! Much bigger than other Flowmaster mufflers I've delt with - and as heavy as the stock muffler. (See Pics Below)
Laying on my back, i supported the new muffler with my knees and guided it into place. Not an easy task, but doable. Once the slip fit over one front pipe, and the bolts in place for the other side, it stayed up well.
HINT: Don't over-tighten the 2 flange bolts next to the slip fit connection. They will bend the round flange and create an exhaust leak.
HINT: Remove the stickers on the rear pipe section before you install them. Otherwise they'll smell and cook off. I used an old razor blade to peel them off.
The rear clamp/mount is difficult. After sliding the new rear exhaust pipe through the truck and into the muffler, I had to tighten the clamp to hold the muffler in place, as well as hold the new pipe in the slip fit connection. The trick here was to push the muffler as far forward as possible, and pull the clamp as far rearward as possible - bringing the clap as close to the fitting as possible. (See pic for description)
HINT: The "washers" on the rear clamp, they're not washers. I crushed them thinking they were washers, but upon further inspection of the instructions, they were designed to prevent the exhaust from slipping of the rubber post mounts. Don't make the same mistake I did.
All bolted up and ready to go, right? Cool.
PROBLEM! Almost immediately after my test drive around the block, i noticed the rear pipe had rotated in it's slip-fit conneciton, allowing the tip to rest against the fender. This caused the fender to melt against the tip and make a mess. After re-tightening, clamping, re-tightening, fidgeting, and some more re-tightening, I finally got the rear exhaust pipe to stay in place without rotating and resting against the fender. This was VERY frustrating, and I would strongly recommend having the rear section welded to the muffler to prevent this.
My initial impressions were not good - as I couldn't get the pipe situated. Also, i felt the exhaust tone was too quiet and didn't notice a signifigant improvement in power. The exhaust tip seems a bit large (3.5"), but it's grown on me since I've installed it. I still might change it to a smaller size (3") in the future.
After a few weeks of driving, I'm much happier with the system. The pipe fitting issue seems to be fixed. The exhaust tone has 'loosened up' and become a little more noticeable, and it exactally where I would want it. I've noticed a power gain between 2000 and 4000 RPM at part throttle and WOT. I haven't noticed ANY loss of torque (good!). Unfortunately, I haven't experienced much of an increase in MPG - maybe about 1/2 mpg.
Overall, I would give the system a 7 out of 10. It had a fair price, is well constructed (except for the pipe fitting issue), and complete with good instructions (which I suggest you read).
-Brad
PS - can someone host and post pics for me?
