i have a 96 xlt with the 5.8. could someone tell me wht the diameter of the inlet and outlet is on the muffler. i know its 26" long.

thanks.

 

OEM muffler is 2" IN/OUT if I recall correctly. Its been a while since I've had the OEM equipment though, might want to wait for a few more responses.

 

I don't know about 80+ models, but my 79 has a 2.5" inlet/outlet.

 

i just went through the whole ordeal. There really is not any choice in the matter. What i was told is that... with the 96, (i have a 5.8), i dont know about the 5.0., there is no good way to fix the problem... except if you have the ability to weld. i was told and saw that no oem muffler is available for this year. for some reason its only the 96, and its becuase of the 3 point flange on the inlet of the muffler.( the distance is so small from the muffler to the flange to the cat, that there is really no place to put on a u-bolt if you cut part of the pipe out.) i understand that they dont produce this part of the assembly any more and mine had to be custome shipped from california where is was in inventory). subsequently, it was easier to wait on the part from california, and i had the shop order the complete setup from the flange back. it was a total pain in the butt, my father in i couldnt even get the flange off with a angle grinder and sawzall. in all total it was about 350, including the shop labor. the muffler was 150 the pipe was about 70 i think and then labor and misc parts including the flange. my big decision in putting a low end system back on was that it was 350 instead of the 500+ getting a bassinni system put on, and welded in a custom shop.

i hope this helps, i wish i would have known before i went ahead and got the 95 system and had to return it, before i waited three weeks with the truck in the shop... next time, when i have more money im going to get the high end system

 

What are you talking about?? I have a 96 bronco, I cut the OEM muffler off and bolted in a flowmaster 40 muffler, I used clamps (u-Bolts).

 

did the flowmaster have extra pipe, and did you set it back farther? like i said, i would have went with the aftermarket except i would have had to get the whole system, why halfa$$ quality. i we tried, with what was supposed to be an oem muffler, and we couldnt get the ublot on,

with out the after market, i was told this was the only way to replace stock with oem...

do you own the 5.8? how do you like the flowmaster 40?

 

i see the 3 flange bolt and the sort distance between the muffler and the flange but im sure an aftermarket muffler can be bolted on. i just need to knwo the inlet outlet diameter.

 

Yes I did extend the pipe because the muffler was shorter than oem, but that was only 5 bucks. I like the flowmaster 40, sounds great. I installed an e303 cam as well so you hear that through the exhaust. thump, thump, thump.

 

im going to have to go with the 2 inch on that too, if my memory serves me right. im just guessing, but is there pipe on the inside of the muffler, which would be accessable if the front of the exhaust cylinder was cut off, that would give you more space if you had a tool that would cut around there. we didnt have a cutter small enough, or the time for that matter. but that would give you more to bolt to. did you try fitting the ubolt on there now, with the muffler in place, i couldnt find an angle that would fit

 

i think....THINK, there is a flange that bolts up to the 3 bolt on a 96 so you can put a aftermarket system on with no trouble

 

I'll post some pics if it ever stops raining out.