The V6 Mustang provides a way to own a pony car that gets better gas mileage and is cheaper on your wallet than the V8. Additionally, there are many who do not need an extremely powerful car, but still want that muscle car look. While the V6 Mustang can accommodate those individuals, they often end up with the highly muffled sound of an economy muscle car with the obvious lack of a second muffler. If you are looking for that increased grumble and look of a GT, New Take Off has a solution for you, and we are going to show you how it’s installed on an S197 Mustang.
The S197 V6 Mustang
The standard engine is a 60-degree 4.0-liter SOHC V-6. It replaces the 3.8-liter 90-degree pushrod engine in the 2004 model, and the 210-horsepower, 240 pound-feet engine gains 23 horsepower and 15 pound-feet. It is smoother and more compact, providing more power and torque. Although that may not seem like a lot, the S197 V6 produces about the same average horsepower as Fox Body Mustang, though its frame weighs about 400 pounds more.
Exiting from two separate three-cylinder banks, the exhaust makes its way independently through two catalytic converters, before being crammed through a single 2.5-inch pipe. The exhaust then goes down the right side of the car, up over the axle, and out through a single muffler. While the S197 V6 has only one muffler, it is based off the GT chassis that has provisions for a second.
The New Take Off / Pypes V6 Dual Exhaust 
The NTO / Pypes exhaust is one of the least expensive stainless exhaust systems you will find. Since NTO deals with direct OEM parts, they opted to retain the stock GT mufflers in the kit, and they turned to Pypes, which designed an X-pipe and mid-pipes that conjoin the factory mufflers to the V6 catalytic converters. The exhaust is fully
stainless (including the mufflers), with 2.5” tubing all the way back, and the kit even includes the factory exhaust hangers for the driver’s side muffler mounting location. It is relatively easy to install, although it does require a slightly higher level of knowledge than a typical exhaust installation, because you must cut the factory Y-pipe off (which is welded to the catalytic converters), and cut the rear bumper to make way for the second muffler.
Features
• After Cat Stainless X-pipe
• Stainless 2.5” Mid-pipes
• GT Takeoff Axle Back OEM Mufflers
• Stainless Steel Tips
• All OEM Style Hangers
• Template for modifying rear bumper
Removal and Installation of the Exhaust
After getting the Mustang up on a lift or jack stands (and allowing it to cool), start by removing the muffler and mid-pipe. The muffler comes off with a C-clamp near the back side of the axle tube. Once the clamp is fully loosened, pry back the metal on the end of the sleeve on the muffler - this will make for an easier removal from the mid-pipe.
Next, remove the two bolts that hold the mid-pipe to the Y-pipe, and use a screwdriver to lift the lock off the sleeve, sliding it back, and remove the mid-pipe from the rear muffler. Once the mid-pipe is out of the way, slide the muffler off its two exhaust hangers, making sure to keep the clamp that holds the Y-pipe to the mid-pipe - you will reuse it later.
Since the stock Y-pipe is welded to the catalytic converter, you will need to cut it to make way for the Pypes X-pipe. We lined up the X-pipe to the Y-pipe (hanger to hanger), made a measurement of 7.5 inches for our cutting spot, and marked the position where we wanted the X-pipe to end up once slipped into the exhaust. The instructions say seven to eight inches, but if you are unsure, cut less and check the length. Once cut flat, use a file or deburring bit to clean up the pipe.
Once the stock exhaust was completely out of the way, we slid the C-bolt clamps (included in the kit) onto the X-pipe, and installed the X-pipe onto the cut portion of the exhaust. The Pypes X-pipe has a reducer on the end to make a tight fit onto the factory piping. Once the X-pipe is leveled, snug the clamps.
The Pypes mid-pipe fits in perfectly, reusing the stock exhaust coupler. 
Reusing the stock exhaust coupler, we then moved to installing the passenger side mid-pipe over the rear axle. Snug the coupler to hold it in place, but keep it loose enough to adjust the pipe to the muffler. Slide the GT passenger side muffler onto the hangers, and use the clamp that is tack welded to the muffler tubing to secure the mid-pipe to the muffler. Spraying a little penetrating lube on the end of the mid-pipe will allow it to slide on more easily. The GT tips will stick out farther, and you will have a little room for adjustability. We slid the muffler back until it sat 3/4 the way back on the hanger. Once the passenger side is set up to your liking, tighten all of the clamps down.
Be very careful when cutting the rear bumper for the driver's side muffler. 
The one part of the installation that needs to be done correctly the first time is cutting the rear bumper. We used the supplied template to outline where we needed to cut, but we also verified other measurements on our own. We verified height by measuring the gap from the bumper body line above to the passenger side cut out, and also measured the distance from the license plate molding line to the center of the exhaust cut out. From there, we slowly cut the bumper with a cut-off wheel, and finished it off with a deburring bit to clean up the plastic bumper. In the end, the cut looked as if it had been done at the factory.
Depending on options and generation, some V6's may come with the factory muffler hanger holes tapped. In our case, the slugs were there, but were untapped. You will need to use an 8x1.25mm tap in the 4-bolt hole slugs, two per muffler hanger. The bolts (included in the kit) will work perfectly with the supplied muffler hangers.
The remaining part of the installation is simple. Hook up the driver's side mid-pipe and muffler in the same fashion as the passenger side, align everything, and tighten down all of the bolts.
Once we were finished, it was time to hear what she sounded like!
Sound and Driving Impressions
The first time the car was fired up on the rack, the sound difference was immediately noticeable. The quiet V6 had been transformed into a slightly tamer (but close) version of its V8 big brother. There is no rasp through the 4.6-liter mufflers, and we even got a few aggressive “grumbles” on acceleration. Driving around town is peaceful - the exhaust is obviously louder, but thanks to the OEM mufflers, it lacks the drone.
The V6 roars significantly louder under full throttle than stock, and it keeps a nice tone throughout the entire power band. While we netted a slight increase in power, the most noticeable difference was in the crisp tones. With a few basic tools and a couple of hours, we were able to change the look and sound of a tame S197 V6 into a snarling, GT-sounding Mustang.
Source: New Take Off
Web:
www.newtakeoff.com
Phone: (888) 240-0025
Linear Mode
