Installing a Cat Back Exhaust System

a Cat Back Exhaust System
  • 3-6 hours
  • Intermediate
  • 65-150
What You'll Need
New exhaust
What You'll Need
New exhaust

Installing a cat back exhaust system is a tad bit complicated but can be done at home. You will need an extra person to help you on this job. The steps laid out below explain the whole installation process.

Step 1 – Safety Precautions

Installing a cat back exhaust system is a time consuming process and there are several precautions to be taken. Wear your work gloves and safety glasses.

Step 2 – Positioning the Car

Make sure the car is parked in an open area and you have enough work space. You need to create crawl space under the car as you need to access the exhaust. Elevate the car using a jack. Support frame with jack stands.

Step 3 – Removing the Isolator

The tailpipes are connected to the chassis with rubber isolators. Coat the isolator with WD-40 and push it with a screwdriver. At the same time get someone to wiggle out the tailpipe. This push-and-pull motion will facilitate the entry of the lubricant and the isolators will come free.

Step 4 – Cutting the Tailpipes

The next step is to cut the tailpipes using a hacksaw. Starting from the muffler, the tailpipes have to be cut at exactly two inches. This could take a while, so be patient. Once the pipes are cut, they can be easily removed.

Step 5 – Unbolting the Muffler Pipes

Slide in deeper and locate the muffler pipe. These are held in position by the flanges that are located behind the cats. Unbolt the muffler pipe, possibly with the aid of WD-40, and remove the muffler.

Step 6 – Checking for fit

Now that the muffler is out, the next step is to see if the new flanges fit. Slide them over the flange stud and check if the drilled holes coincide.

Step 7 – Installing

Now slide the new muffler assembly over the flange studs. Do not introduce the nuts as of now. One person will have to hold the unit in place, while the other connects the hangers on the muffler to the outlet pipes.

Step 8 – Introducing New Tailpipes

Let the car remain on the jack stand, but lift the body with a second floor jack. This increase in space will help in sliding the tailpipes in, around, and through the suspension as you maneuver it into position. Now lower the car's body into original position.

Step 9 – Tightening the Flange Nuts

The complicated part is over. Now you need to align and tighten the units. Tighten the flange nuts with a wrench. This will modify the clearance between the bumper and the tailpipes.

Step 10 – Installing Exhaust Clamps

Install the exhaust clamps to the inlet pipe and muffler unit. Make sure the clamps are secured tight. Also tighten the clamp on the muffler and tailpipe unit.

Step 11 – Checking for Discrepancies

Examine the unit and see if there is any alignment issue. Make sure there is nothing interfering with the tailpipes. The suspension and chassis are always located very close to the tailpipes, but make sure they are not touching each other.

Step 12 – Final Step

Get the car back in position by removing it from the jack. Start the engine and enjoy the powerful sound generated by the newly installed cat back exhaust system.