I bought a 95 Bronco. THe previous owner has the exhaust split w/ a y-pipe then into 2 dynomax mufflers then dumps 2" past muffler. This is not emissions legal so I have to change it. Should I go back to one muffler one pipe or leave it two. If I do leave it as 2 where should they exit, driver & pass before the tire, straight back or 2 on one side before the tire like the Lightning? Thanks for the help.

 

I have 2 1/4" dual exhaust on my '90 Bronco(302).I've never had any problems passing emission testing in PA.I have two convertors,two Flowmaster series-50 mufflers,and then the tailpipes come straight back,and exit out the rear of the truck,under the rear bumper on either side.The only thing is sometimes when stuck in traffic,if you have the rear window down,some exhaust fumes can get in the back.If you don't open it often(I don't...),or it doesn't work well,having the pipes exit the back would be okay.The muffler shop did suggest having the pipes exit on either side,just behind the rear wheels,however.I see a lot of Broncos with the same set-up as mine,so I guess it all boils down to the "look" you want your Bronco to have.I'm really pleased with the custom bent system I have on my '90.Good luck.

 

I have a 91 w/ a 302. I went with shorty headers (smog legal), 1 cat, cut the 2nd off to get a little more flow. Still legal though. And single out behind right rear tire. Looks and sounds great. If I were to change anything though, I would probably go with the 40 series Flowmaster rather than the 50 series, just to be a little louder. It actually had quieted down from the exhaust leak that I had from a cracked stock manifold and also had a glass pack on(didn't like that at all)

I do like to run with my rear window open and that is the reasoning for not going out of the rear.

Alot of people seem to be running single 3" but I went with single
2 1/2". I was worried about loosing too much back pressure on the 302 without the 2nd cat and a 3 " exhaust.

I thought about 2 1/4" split out of one muffler and having it exit just before the rear tires. A buddy of mine made me second guess myself on it thinking that the exhaust may get crushed when wheelin' if you get in a hairy situation. Not sure if that could happen, but just raised a question though.

 

What kind of headers did you use?

 

Just about anything you do AFTER the cat should be legal, as long as it meets the local noise regs. I can imagine that the problem is with the pipes exiting 2" after the muffler, as most safety inspections will require the exhaust to exit out beyond the side panels of the vehicle (not under the floorpan). Have you considered a single inlet/dual outlet muffler (with dual tailpipes)? I had a Flowmaster SUV 50 series installed with two tailpipes - one exiting behind the rear wheel on either side, and have been very happy with it. A word to the wise..... don't run your pipes straight out the back, as you see done on many of the pickups out and about. If you have as much as a tiny gap between your rear glass and the seal, the fumes will be sucked right into your interior. Running them out to the sides puts them into the air blowing by your truck, and they're not recirculated up into the back. Good luck!

 

I have the Flowtech shorty headers. They have a 3/8" flange and haven't had a problem with leaks to this point. This was a concern as many people that I talked to mentioned that if the flange was thin, you will probably get leaks.

Since the paint from the factory chips easily and isn't heat resistant(it's put on to limit rust during shipping) I had mine ceramic coated to help with longevity of the headers and to avoid seeing the nasty rusted headers develop over the next weeks or months to come. The company that did the ceramic coated also polished the headers so they look like they are chrome. Look pretty good.

Good luck with your quest.

-Anthony

 

I am getting ready to install a set of shorty headers on my 89 Bronco.
Would like to know what company ceramic coated yours and what it costs?
Thanks,
Don