[nightsurge]

I recently bought the Flowmaster American Thunder catback exhaust and H-Pipe for my 2000 V6 Mustang and had it installed by a local shop, FAIR Muffler and Brake. I used a Pypes hanger kit for the install.

Within a day I started hearing a rattle on the passenger side at low RPM/idle/reverse and when going over bumps. Also, a slight rasp/buzz occurs at ~3000 RPM on the passenger side only. Then a much louder rattle on the driver side started happening. The rubber bushing of the rear bumper hanger on the driver side had somehow popped out, so I pushed that back in and put a hose clamp there to temporarily hold that in place.

Then I looked on the passenger side. Everything seemed to be snug, and I felt space between the pipes and any part of the frame/fueltank/etc that I could tell, but I did notice that one of the hangers was not installed. The hanger that attaches to the muffler and goes outward from the center looked like it was cut-off and I could see no attempts to mount the hanger to the car at that spot. I also noticed that instead of using the exhaust clamps that came with the kit, the mufflers were welded to the kit. I had thought that only the H-Pipe would need welded since I originally had a Y-Pipe and I bought an adapter that reuses the cats. One of the stock hangers from my old exhaust was left on, but that is not a big worry as I can remove that myself.


Back view


H-pipe weld


missing hanger


bushing popped out

So, what are my issues here? When I asked, the technician guy said there was no issues with installation and that they used a few parts from each kit (Flowmaster and Pypes mixed and matched hangers/etc) to finish it.

Poor installation? Faulty baffle in the exhaust? Bad Pypes hanger? All the above? They even kept my unused parts from the kits which I have now requested to have back since that is my property and they did not ask to keep them.

[6ER THEN I 8ER!]

Go get your parts then go to another shop for a second opinion...have you pin pointed theeaks yet? I'm guessing either bad welds or where your adapter connects

[nightsurge]

^I am not certain anything is related to leaks yet. Seemed like just a poor mounting job was the cause of the rattles. The rasp/buzz at 3000 RPM I have no idea what that could be, but have heard tightening clamps fixes it, or it's a bad baffle which needs RMA'd to Flowmaster.

You think the rasp/buzz is a leak somewhere?

[SlowSix]

Exhaust leak is a tick not a rattle.

I had a couple rattles in mine that I had to fix...one was my passenger break line was hitting my tail pipe...second was my tailpipe hitting the gas tank cover

[nightsurge]

Originally Posted by 01SilverSixer Exhaust leak is a tick not a rattle. I had a couple rattles in mine that I had to fix...one was my passenger break line was hitting my tail pipe...second was my tailpipe hitting the gas tank cover

How did you fix the rattle/get more clearance? Just keep adjusting things? Since the geniuses welded the mufflers to the rear pipes instead of using the clamps, I don't think I can adjust it much.

[WhiteShadow]

not like you have to do this, but getting everything hard welded together can make a difference than just having it bolted together after the h pipe and stuff. like sixer said go to another shop and have them check it out. try to find one of the best rated for your area and see what they say.

[flowmann]

Originally Posted by nightsurge How did you fix the rattle/get more clearance? Just keep adjusting things? Since the geniuses welded the mufflers to the rear pipes instead of using the clamps, I don't think I can adjust it much.

Nightsurge - Did you get this fixed? Cutting the hangers off the pipes in front of the axle was a bad idea. Did they add new hangers in that area? If not, the rear hangers are going to take the brunt of the weight and not be as effective at controlling the position of the exhaust.

[nightsurge]

Originally Posted by flowmann Nightsurge - Did you get this fixed? Cutting the hangers off the pipes in front of the axle was a bad idea. Did they add new hangers in that area? If not, the rear hangers are going to take the brunt of the weight and not be as effective at controlling the position of the exhaust.

It was just the outer hanger. The inside one is still there and being used. I took it in and according to them, the outer hanger is not necessary as the inner one is enough to hold it, and it is the rear hanger on the passenger side that is creaking/rattling. I am going to lubricate it and maybe put some new rubber bushing there.

It is hitting the rear axle over bumps, but there is nothing I can do. It has plenty of clearance, but still touches. So I can replace my rear shocks or dent the pipes where they are hitting, but that's about it.

Also, just put on my tune and it seems to not rasp/vibrate any more at 3000rpm/idle, so that's good! Overall pleased with the system and sound.