Converting Your Mustang V6 to Dual ExhaustLast Updated August 10, 2023 | Andrew Boyle
Throaty Exhaust Note, More Flow & Better Gas Mileage!
All of these things and more are reasons 1994-2010 V6 Mustang owners should consider swapping out their quiet, restrictive factory single tip exhaust for a more free-flowing, throaty dual exhaust system. Dual exhaust conversion kits will not only offer your Mustang a better exhaust note, but they’ll also free up power at the top of the powerband and help a bit with those MPGs!
For single-tip exhaust systems, the process to switch over to dual exhaust isn’t too difficult. It requires the purchase of a dual exhaust conversion kit, sometimes a couple extra exhaust hangers and cutting a small divot in your bumper for 2005-2010 Mustang owners. Aside from that, the process is simple and straight-forward, especially if you’re familiar with your Mustang’s exhaust system already!
1994-2004 V6 Mustang Dual Exhaust Conversion Process
For those of you who are proud SN95 or New Edge V6 Mustang owners, the process to allow that 3.8L V6 motor to breathe a bit better is relatively simple. This is due to the fact that most dual exhaust options for the 3.8L V6 include a Y-Pipe rather than an X or H-Pipe. This makes installation a breeze due to the fact it’ll bolt right up to your factory manifolds. Technically, exhaust flow would be better with an X-Pipe or H-Pipe, but the installation would be quite a bit more difficult and part options for that combination are limited. Check out our other tech article to learn more about the differences between a Y-Pipe, H-Pipe and X-Pipe!
For 1999-2004 Mustang owners, if your kit doesn’t include them already, you’re going to want to make sure that you pick up the Ford Exhaust Hanger Kit that includes the additional exhaust hangers needed to complete the installation. Keep in mind that the kits for the SN95 (1994-1998) and New Edge (1999-2004) are different, so be sure to pick the correct kit that fits your particular Mustang.
Once you’ve got everything that you need to properly mount your new dual exhaust kit and additional muffler, you’re ready to get the car on a lift or a jack and jack stands to pull the old exhaust off and replace it with your new system. Keep in mind, that some of your exhaust bolts may be seized due to old age and mother nature. Use a penetrating oil to soak before attempting to crank on your old exhaust hardware. Aside from that, you should be back on the road in no time!
2005-2010 V6 Mustang Dual Exhaust Conversion Process"...higher power numbers out of an H or X-Pipe"
The exhaust system on the 4.0 V6 in the 2005-2009 and 2010 Mustangs is a bit easier to work on and modify due to its design. With that said, you do have the option of using a different mid-pipe to allow for more flow and a true dual exhaust design. This means that you’ll upgrade your Y-Pipe for an H-Pipe or X-Pipe to see the performance benefits of a free-flowing mid-pipe. There’s nothing wrong with the Y-Pipe option included in some kits, but you’ll definitely see higher power numbers out of an H or X-Pipe.
Keep in mind, that most of these kits will require you to cut your factory Y-Pipe off to clamp in your new mid-pipe!
There are plenty of options when it comes to dual exhaust for your 2005-2009 or 2010 V6 Mustang. With options from Borla, Magnaflow, Flowmaster and Ford Performance, you’ll be able to nail down the exhaust note that you’re looking for from your powerful V6 engine!
For 2005-2010 V6 Mustangs, you’ll want to be sure to grab a dremel tool and be prepared to cut another divot in the driver side of your rear bumper to match the passenger. Aside from that and the cutting of the Y-Pipe, installation is fairly simple and straight-forward. Most kits also include an additional exhaust hanger for an easy install as well.
Tech Tip: If you don’t want to cut into your bumper, you also have the option of swapping to a GT or GT500 rear bumper cover for 2005-2009 Mustangs. And for 2010 V6 Mustangs, you can swap over to the GT rear valance. That way, you’ll have dual exhaust cutouts without the potential of messing something up if you’re cutting by hand.
Related: If you want to know how to convert a classic Mustang to dual exhaust, check out our classic Mustang x-pipe installation guide.
A Note About Backpressure
Unlike a V8 which boasts much more power than a V6, the V6 engines are more reliant on exhaust backpressure for low-end torque. What does that mean? Well, low-end torque is the immediate seat-in-the-pants feeling you get upon hitting the gas pedal in the low-mid range of your RPM band. When you introduce an additional set of exhaust piping to your system, such as a dual exhaust conversion kit, some of that low-end torque may be affected. Meaning, you’ll see higher peak power numbers at the top of your power band where the exhaust gases can escape quicker, but down low your torque numbers may fall off a bit.
There are a couple of things you can do to alleviate the small drop in low-end torque:
- Pick up a dual exhaust conversion kit with a chambered muffler for naturally aspirated applications.
- Add a set of shorter rear gears for better acceleration.
- Add a tune for better throttle response and better acceleration.