Shorty install Fail - Ford Mustang Forum
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post #1 of 22 (permalink) Old 06-08-2016 Thread Starter
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Shorty install Fail

I knew the header install on the mustang was bad but this is my second failed attempt. Sprayed the 2 nuts near the collector with PB Blaster and left overnight but they still won't budge! Running out of options other than having a shop do it. Not having a lift and air tools blows. Anyone have any tips before I give up?

Also noticed a section of one of my exhaust piping to be slightly flattened, not sure how much of an issue this is. Probably came from the factory like this but obviously I find this out only after the warranty ran out earlier this year....

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post #2 of 22 (permalink) Old 06-08-2016
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In my limited experience if a nut is that corroded it will take heat or cutting to get it off. A shop should not charge that much to do the job. Take the car to one for an estimate.


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post #3 of 22 (permalink) Old 06-08-2016
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Torch it red hot.
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post #4 of 22 (permalink) Old 06-08-2016
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the flat spot is from a speed bump more than likely, didn't come from the factory that way. if you don't have access to a torch set up, you can try the butane flame canisters for a lot cheaper. they don't get as hot but still may work. I used one on the rear pinion driveshaft bolts (heated the flat mating surface) and had success. not sure why Ford chose to use star point driveshaft bolts. PITA. that was on my 93' but anyway....good luck
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post #5 of 22 (permalink) Old 06-08-2016 Thread Starter
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Quote:
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the flat spot is from a speed bump more than likely, didn't come from the factory that way. if you don't have access to a torch set up, you can try the butane flame canisters for a lot cheaper. they don't get as hot but still may work. I used one on the rear pinion driveshaft bolts (heated the flat mating surface) and had success. not sure why Ford chose to use star point driveshaft bolts. PITA. that was on my 93' but anyway....good luck
If I had a lift I would be good with torching the damn things but crawling under the car with a torch and with the location being so cramped it's a disaster waiting to happen. I should leave this one up to the experts as advised by Kenv.

If it was from a speed bump both pipes would be dented equally or at least scrape marks should be visible on the other. A hit like that would have made quite a noise too and no one else drives my car.
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post #6 of 22 (permalink) Old 06-08-2016
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Did you buy your car new or used? Isn't that the spot that the factory resonators are normally located or do the V6s not come with the resonators?

Either way, check to see if the other pipe has the same flat spot along the top of the pipe in the same place. My guess is that the flat spots are from the factory as they are on the GT resonators.
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post #7 of 22 (permalink) Old 06-08-2016
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Quote:
Originally Posted by bl817 View Post
the flat spot is from a speed bump more than likely, didn't come from the factory that way. if you don't have access to a torch set up, you can try the butane flame canisters for a lot cheaper. they don't get as hot but still may work. I used one on the rear pinion driveshaft bolts (heated the flat mating surface) and had success. not sure why Ford chose to use star point driveshaft bolts. PITA. that was on my 93' but anyway....good luck
The Flat spot is there to make the left pipe and the right pipe different to get rid of drone in the factory system.
As for getting the nuts off of the mid pipe. I did mine in my garage with the car on jack stands, you need extension long enough to get down below the pipe and a breaker bar with an extra piece of pipe that slides over the breaker bar for a cheater. They will either break loose or break. I had to cut 1 of mine off with a 4.5 inch grinder with a metal cutting wheel.

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post #8 of 22 (permalink) Old 06-08-2016 Thread Starter
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You're right it's by design, I see peeps on other forums worrying about the same flattened section.

I used a 10 in. extension with a breaker bar and didn't have any room to turn the bar. I'll have to buy the 20 in. extension and give it a go. Thanks!

Do you know if yours had resonators? I don't recall seeing them on mine, I'll have to check tomorrow.
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post #9 of 22 (permalink) Old 06-08-2016
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Quote:
Originally Posted by Masterang View Post
You're right it's by design, I see peeps on other forums worrying about the same flattened section.

I used a 10 in. extension with a breaker bar and didn't have any room to turn the bar. I'll have to buy the 20 in. extension and give it a go. Thanks!

Do you know if yours had resonators? I don't recall seeing them on mine, I'll have to check tomorrow.
The Resonators are right after the bend at the bottom of the Catalytic converter.

One of the nuts on the right side is hard to get too even with the extensions, but using more than one makes it easier to get down below the mid pipe.
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v6 and 5.0's had different over axle pipes. V6 had flat spots and 5.0 had resonators.

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post #11 of 22 (permalink) Old 06-11-2016 Thread Starter
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Hi all,

I (barely) managed to get the 2 nuts at the collector end out with an impact wrench so that problem is solved. Torching it did not work as well, $400 later and 1,100 reverse torque impact wrench worked it's magic.

The first 13mm nut at the engine block end was ok coming out (Pic 1) the rest are all rusted tight. I took the impact wrench to the lower ones and the stem from the engine block came off with the rusted nut still in place!, see Pic 2. Can I just put some red loctite on there and thread it back into the engine block or is this a bigger problem?? Thanks.

Edit: Not an issue, the spindle comes out and new bolts from the manufacturer go in.
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Last edited by Masterang; 06-11-2016 at 11:34 PM.
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post #12 of 22 (permalink) Old 06-11-2016 Thread Starter
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Quote:
Originally Posted by Blackpenguin69 View Post
v6 and 5.0's had different over axle pipes. V6 had flat spots and 5.0 had resonators.
V6 has resonators too.
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Quote:
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V6 has resonators too.
like I stated, v6 doesn't have them on the over axle pipe.

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Mine has the same dent on the passenger side, in my opinion is from the factory but i could be wrong.

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post #15 of 22 (permalink) Old 06-11-2016 Thread Starter
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Mine has the same dent on the passenger side, in my opinion is from the factory but i could be wrong.
Yes it's from the factory, not a problem.

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