Upgrading your Mustang’s exhaust system is one of the most rewarding modifications you can make, and the Roush 5.0LV8 Cat-Back Exhaust Kit for 2018-2025 Mustangs delivers both a powerful growl and optimized performance. If you’re ready to give your Mustang a more aggressive sound and improved exhaust flow, this step-by-step installation summary will guide you through the process.
Below, we’ve summarized the key steps from the Roush installation manual to make your installation as straightforward as possible. Be sure to reference the full manual for detailed diagrams and safety notes before beginning the installation.
Tools You’ll Need
Before starting, gather the following tools to ensure a smooth installation:
- Safety glasses
- A socket wrench set (with 13mm and 15mm sockets)
- Ratchet or impact gun
- Exhaust hanger removal tool
- Torque wrench
- WD-40 or another lubricant
- Jack and jack stands (or a lift)
Step 1: Prepare Your Mustang
- Safety First: Park your Mustang on a flat, stable surface, and allow the exhaust system to cool down completely.
- Lift the Vehicle: Use a jack and jack stands or a lift to raise the rear of the vehicle, providing safe access to the undercarriage.
- Spray Lubricant: Apply WD-40 to all exhaust hanger isolators to make removal easier.
Step 2: Remove the Factory Exhaust System
- Loosen the Clamp: Locate the clamp connecting the factory mid-pipe to the catalytic converters and loosen it with a 15mm socket.
- Detach the Muffler Hangers: Use the exhaust hanger removal tool to disconnect the muffler hangers from the isolators at the rear of the vehicle.
- Remove the Factory Exhaust: With the clamps loosened and hangers disconnected, carefully slide the factory exhaust system out and set it aside.
Step 3: Install the Roush Cat-Back Exhaust System
The Roush Cat-Back Exhaust Kit is designed for easy installation with factory mounting points and no welding required.
Install the X-Pipe Assembly
- Slide the supplied x-pipe into the mid-pipe area where the factory exhaust was removed.
- Reuse the factory clamps to secure the x-pipe to the catalytic converters, but do not fully tighten the clamps yet.
Attach the Over-Axle Pipes
- Slide the over-axle pipes into the x-pipe outlets.
- Position the pipes to route over the rear axle, ensuring they are not contacting any components.
Mount the Muffler Assemblies
- Connect the mufflers to the over-axle pipes using the supplied clamps.
- Reattach the muffler hangers to the isolators at the rear of the vehicle.
Adjust and Align
- Align all pipes and mufflers to ensure proper fitment and clearance.
- Ensure the tips are centered within the bumper cutouts and evenly spaced.
Step 4: Tighten and Torque
- Starting at the front of the exhaust system, tighten all clamps with a 15mm socket.
- Use a torque wrench to tighten each clamp to 45 lb-ft, as recommended in the manual.
- Double-check that all components are secure and that the exhaust system has sufficient clearance from the body and suspension parts.
Step 5: Final Inspection and Test
- Lower your Mustang and inspect the exhaust system from underneath to ensure everything is properly secured.
- Start the engine and listen for any exhaust leaks. If necessary, adjust the clamps or pipes to resolve issues.
- Take your Mustang for a test drive to enjoy the enhanced exhaust note and verify that all components remain secure under driving conditions.
Tips for a Successful Installation
- Take Your Time: Precision is key when aligning the exhaust system to ensure proper fitment and avoid leaks.
- Use Lubricant: Spray WD-40 on stubborn hangers or clamps to make disassembly easier.
- Double-Check Clearances: Make sure no part of the exhaust system is in contact with the body, suspension, or other components to prevent rattling or heat damage.
Upgrade Your Mustang’s Sound Today
Installing the Roush 5.0L V8 Cat-Back Exhaust Kit is a straightforward process that can be completed with basic tools and a bit of patience. This kit not only transforms your Mustang’s exhaust note with an aggressive rumble but also improves performance with optimized exhaust flow.
For more information, detailed diagrams, and torque specifications, refer to the full Roush Installation Manual. Ready to make the upgrade? Explore this exhaust kit and more at Roush Performance!
