Magnaflow Catback and Mid-Pipe Instructions

[cvp33]

I'm posting this to help all the do-it-yourselfer's out there. If you can find someone to install this exhaust for under $150 bucks, I suggest you let 'em. If you're a die hard like me, then here ya' go:

Magnaflow Exhaust Instructions

1) Get your SRT-8 in the air. Jack stands, ramps, whatever you feel comfortable with.
2) Set the emergency brake.
3) Pop trunk and disconnect your negative cable to protect electronic components.
 Remember to leave the trunk open. With battery disconnected you will not have access to the trunk unless you crawl through the rear seat.
4) Disconnect the O2 sensors.
 Do not bother trying to unscrew the connectors as it’s much easier with the exhaust dropped. And trust me you do NOT want to damage these.
 The front O2 connectors sit up high near the engine. You can reach it though.
5) The cat bolts are 5/8th’s and a deep socket or spark plug socket works well or a box wrench with a ratchet head.
6) Once you break the cat bolts loose the nuts come off by hand.
7) Remove the center support, 4 bolts. (I did not re-install mine, but some will choose to keep it)
8) Remove the driver’s side muffler beginning at the resonator.
9) None of the bolts are re-used so place these in a ziploc bag should you ever decide to return to stock.
10) As you unbolt the remaining pieces of the exhaust be sure not to damage the rubber hangers. These are re-used to mount the Magnaflow exhaust.
 Pulling off the rubber hangers can be a bear. I suggest spraying WD40 or other lubricant on first to give you a little help. Also leave the rubber hangers on the body and push the exhaust pieces on to the bushings. It’s not easy, but I didn’t see another way to do it.
11) Once the entire exhaust is removed you can now drop the cat pipes. Don’t forget left side and right side as your O2 sensors are still attached and need to go back on the proper sides. (not sure that this would throw an engine code, but why risk it)
12) Lay the Magnaflow cat pipes next to the stockers and it will be easy to see which side is which. (they are not labeled)
13) Now remove the O2 sensors from the stock pieces and install in the Magnaflows.
 I put a dab of anti-seize on for good measure. Be sure you don’t get any on the sensor itself, ONLY the threads.
14) Now re-install the cat pipes.
 Again, I like to put a dab of anti-seize on the cat bolts.
 I aligned these and torqued these as hard as I could. Too tight for a torque wrench unfortunately. This is the only part of the exhaust I would tighten at this point.
15) Re-connect the O2 sensors. They only go one way so you can’t get it wrong.
16) Work your way back through the exhaust system. Be sure to put the 2.75” and 3” clamps on prior to snugging up the pipes. Leave all the exhaust loose at this point.
 Connector pipes
 Resonator (pretty polished stainless – you gotta love aftermarket exhausts)
 Mufflers
17) You can hang the exhaust on the rubber mounts but again don’t tighten anything yet.
18) Now that everything is in place and loose you can manipulate the exhaust, starting at the tips. Once these are in place tighten the first clamps going from the muffler assembly to the resonator.
 I found that having someone hold the muffler in place while I tightened worked the best
19) Now work your way up the exhaust straightening and tightening as you go.
20) This is where you would re-install the cross brace if you choose.
 No it’s not a driveshaft loop
 No it’s not there for torsional frame rigidity.
 Yes do it if it helps you sleep at night.
21) Finally wipe down the entire exhaust system with a quality glass cleaner to remove your body oils, finger prints, blood, sweat and tears, etc.
22) Lower your vehicle
23) Reconnect battery
24) Terrorize the highway

If I missed anything, please feel free to add to this thread. This is meant to "fill in the blanks" of the Magnaflow instructions. Hope this helps somebody.

[So Cal 300]

Originally Posted by cvp33

I'm posting this to help all the do-it-yourselfer's out there. If you can find someone to install this exhaust for under $150 bucks, I suggest you let 'em. If you're a die hard like me, then here ya' go:

Magnaflow Exhaust Instructions

1) Get your SRT-8 in the air. Jack stands, ramps, whatever you feel comfortable with.
2) Set the emergency brake.
3) Pop trunk and disconnect your negative cable to protect electronic components.
 Remember to leave the trunk open. With battery disconnected you will not have access to the trunk unless you crawl through the rear seat.
4) Disconnect the O2 sensors.
 Do not bother trying to unscrew the connectors as it’s much easier with the exhaust dropped. And trust me you do NOT want to damage these.
 The front O2 connectors sit up high near the engine. You can reach it though.
5) The cat bolts are 5/8th’s and a deep socket or spark plug socket works well or a box wrench with a ratchet head.
6) Once you break the cat bolts loose the nuts come off by hand.
7) Remove the center support, 4 bolts. (I did not re-install mine, but some will choose to keep it)
8) Remove the driver’s side muffler beginning at the resonator.
9) None of the bolts are re-used so place these in a ziploc bag should you ever decide to return to stock.
10) As you unbolt the remaining pieces of the exhaust be sure not to damage the rubber hangers. These are re-used to mount the Magnaflow exhaust.
 Pulling off the rubber hangers can be a bear. I suggest spraying WD40 or other lubricant on first to give you a little help. Also leave the rubber hangers on the body and push the exhaust pieces on to the bushings. It’s not easy, but I didn’t see another way to do it.
11) Once the entire exhaust is removed you can now drop the cat pipes. Don’t forget left side and right side as your O2 sensors are still attached and need to go back on the proper sides. (not sure that this would throw an engine code, but why risk it)
12) Lay the Magnaflow cat pipes next to the stockers and it will be easy to see which side is which. (they are not labeled)
13) Now remove the O2 sensors for the stock pieces and install in the Magnaflows.
 I put a dab of anti-seize on for good measure. Be sure you don’t get any on the sensor itself, ONLY the threads.
14) Now re-install the cat pipes.
 Again, I like to put a dab of anti-seize on the cat bolts.
 I aligned these and torqued these as hard as I could. Too tight for a torque wrench unfortunately. This is the only part of the exhaust I would tighten at this point.
15) Re-connect the O2 sensors. They only go one way so you can’t get it wrong.
16) Work your way back through the exhaust system. Be sure to put the 2.75” and 3” clamps on prior to snugging up the pipes. Leave all the exhaust loose at this point.
 Connector pipes
 Resonator (pretty polished stainless – you gotta love aftermarket exhausts)
 Mufflers
17) You can hang the exhaust on the rubber mounts but again don’t tighten anything yet.
18) Now that everything is in place and loose you can manipulate the exhaust, starting at the tips. Once these are in place tighten the first clamps going from the muffler assembly to the resonator.
 I found that having someone hold the muffler in place while I tightened worked the best
19) Now work your way up the exhaust straightening and tightening as you go.
20) This is where you would re-install the cross brace if you choose.
 No it’s not a driveshaft loop
 No it’s not there for torsional frame rigidity.
 Yes do it if it helps you sleep at night.
21) Finally wipe down the entire exhaust system with a quality glass cleaner to remove your body oils, finger prints, blood, sweat and tears, etc.
22) Lower your vehicle
23) Reconnect battery
24) Terrorize the highway

If I missed anything, please feel free to add to this thread. This is meant to "fill in the blanks" of the Magnaflow instructions. Hope this helps somebody.

I'm next.

[lukeinator-8]

very well done. same on my charger rt. i actually had to weld half inch extensions on the frame brace to reinstall without touching or noise. wifes daily driver and that adds to the five star crash rating. did help me sleep at night also. great write up. i literally tightened and loosened the resonators a hundred times to get them perfecto. love magnaflow.

[hemiwagn]

Channel locks (at the widest setting) are useful to squeeze the stock exhaust out of the rubber hanger (lube it first, like you mentioned, WD40, liquid soap, whatever ya got). Oh and don't forget the ground wire (clipped to the forward side of passenger side resonator, at least it was on my mag srt8).