Day 4 (Saturday) :
Install completed. Took our time and spent about 4 hours at a leisurely pace, thinking things through and enjoying the summer-like weather.
My son and I installed the two rear "dual exhaust" pieces prior to install. We then installed that piece on the rubber hangers. We then installed the "Z" pipe, cat/flex pipe & intermediate pipe in that order. We installed the two new rubber hangers and left the connection between the intermediate pipe and "Z" pipe completely off.
We then removed the header. As previously mentioned, had already loosened the bolts and removed the O2 sensors. Quick tip, remember to unbolt the upper bracket on the bottom of the header/cat.
Gave the entire face area of the header interface with very light pressure scotch-Brite and then wiped both faces with alcohol. Put on new gasket. Installed the header with one person up top and one person below. Used
@87ShelbyZ suggestion and put antiseize in the compression area where header and cat pipes meet. Remember to put compression clamp on first and in a position you can tighten it.
Once that was positioned correctly, we installed the new header bolts and nuts at 25 ft lbs. We then tighten header/cat pipe clamp to 35 ft lbs. Tighten cat/flex pipe to existing bracket on the chassis. We then worked out way back tightening all connections to 35 ft lbs.
By the way, I also had to re-use my copper cat pipe flange gasket. I may have used the intended gasket on one of the back connections, or they just did not provide the right one. I also way have used the wrong size bolts at that connection as it was a real fight to get them to go through the re-used OEM gasket. During clean-up, I noticed two smaller bolts which may have been intended for that.
Lastly, we installed both O2 sensors to 30 ft lbs with some antiseize. The O2 sensor which reads post cat requires an extension which is provided. I made sure to keep as far from exhaust piping as possible.
Moment of truth. Started it up and it sounded great right away. A nice, aggressive growl and burble, but not too loud or obnoxious. Also, no smoke, leaks or CELs. Gave it a short Rev and it also sounded wonderful.
To the test drive. Did notice more cabin vibration, however only on startup when idling can I say I really "noticed" it. Could feel it a bit in my ear. Did not have that feeling at any other point in king test drive, even at slow speeds, stopped at lights/stop signs. I think I will take
@87ShelbyZ advice and put something to damper between cat/flex pipe and chassis.
I am so happy with my total setup now. Mechanically/performance, this is what I also hoped my Dart would be. It is my daily driver that I wanted to be fun, usable and makes me smile. I understand it is not a Charger, a WRX, a Focus ST (or even a Fiesta St), whatever, but my head, heart and butt-dyno love it. It is mine and it speaks to me, makes me look back at it and smile.
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