BBK Off-Road X-Pipe Stock/Shorty Headers 4.6L 2V/4V 1999-2004

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Product Description

BBK 2-1/2" Off-Road X-Pipe for 1999-2004 4.6L 2V/4V Mustangs with Stock or Shorty Style Headers.

This BBK direct replacement X-Pipe features 2-1/2? diameter CNC mandrel bent aluminized tubing to ensure maximum flow and horsepower.

OEM-Original O2 sensor locations and factory style die-stamped flanges ensure a perfect fit and BBK In-house dyno-testing has shown solid gains of 15-20 horsepower depending on application.

ALL BBK full length X-Pipes are designed as a direct bolt on to factory header or any aftermarket shorty headers as well as of course BBK shorty headers for weekend track or race use.

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Mustang Applications

This product will fit the following Ford Mustang years:

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Product Video

By Bill Tumas: Most of us can hear a Mustang coming down the road long before we can even see it. These days an off-road pipe and Flowmasters are probably more common than a stock exhaust system. Our 2003 Cobra is actually 100% stock with the exception of a set of welded in Flowmasters. Today we're going to remove the factory H-pipe and replace it with this high flow BBK unit to give our Mustang that classic sound.

BBK's X-pipe comes with a three piece modular design, making it a lot easier to install. You have your main X-pipe here and then the front two pipes disconnect to install on the Mustang. All four bungs for your O2 sensors are already installed, as well. The only thing you'll need for installation is a new gasket for the passenger side.

Before the installation, we'll start it up to give you an idea of a sound clip ahead of time. Keep in mind the only modification currently is a set of Flowmasters. It sounds pretty good. We're expecting some nice gains with our X-pipe.

For this installation you'll need a jack and jack stands or lift, 1/2" ratchet, 15 mm deep socket, 15 mm shallow socket, swivel, an assortment of extensions, 3/8 ratchet, 15 mm socket, 14 mm socket, 15 mm wrench, hammer, oxygen sensor or 7/8 wrench, flashlight, and safety glasses.

To remove our factory pipe, we'll have to remove two nuts off of each of these ends here and two nuts on each side of the front, plus disconnect our oxygen sensors. These sensors will be able to disconnect from here. We'll actually have to get the pipe down to be able to reach the ones on the top because they're near the top of your transmission.

We're going to start with the passenger side. It's the more difficult one to get to. If you'll look you can see the stud with the knot all the way up past our oxygen sensor wire. There's one on the top and one on the bottom. You will need extensions, as well as a swivel, to get to these. The driver's side is a little easier to get to, you can see what you're doing here. Now we'll remove the nuts on the back of the studs here so we can separate our factory H-pipe from our flow tubes.

Now we'll tap the flange just to separate. We'll start by disconnecting the driver's side sensors because you can reach that one a little bit easier, when disconnected, we'll lower down our factory H-pipe. We'll spray some Blaster on these to get them off. Now we can remove the sensors so we can transfer them to our new pipe. They are location specific so wherever you take them off at you want to make sure you put them on the new pipe in the same location.

We're going to start with the flange for the passenger side. BBK provides a little anti-seize packet with their hardware. You want to put a couple of dabs on the oxygen sensor before you reinstall it. We're going to remove our original gasket and replace it with our new pipe. We'll start by putting a new gasket up into place and plug our sensor back in.

Start by connecting the second part of our pipe to our factory exhaust. You'll want to start by lining up the passenger pipe. The reason we start with this one is this pipe is fixed. You really can't adjust it because the flange is flat. You'll want to adjust this and move it so this pipe lines up. If this one is not lined up afterwards the front pipe is a ball end flange so we'll have a little bit of adjustment. We can loosen it up and line it up with this pipe here. You can see this one's off a little bit so we're going to loosen this pipe up, center it a little bit more, and then tighten it back up. Now, we'll start tightening up the back of our X-pipe where it connects to our mufflers. Now, we'll tighten up the clamps.

The last step is to plug in our oxygen sensors. When you're taking the cats off the car you will have to turn the O2 sensors off in some way. When using MIL eliminators this is where you install them. If you're not you can turn off with the tuner, which is what we're going to do with our car. I'll use a zip tie just to tie these up out of the way and our installation is finished.

Now, we'll see how it sounds with the X-pipe. A lot more aggressive, just what we were expecting. Getting rid of our clog stock cats in favor of the BBK X-pipe really woke up our '03 Cobra. Installation should take you no more than around an hour. You should be back on the road in no time.