Help with exhaust system install

[Ron Egan]

I recently purchased a used Ruf dual outlet muffler and Euro pre-muffler. What do I need in the way of gaskets and hardware (size and specifications) to install these ?

Any words of wisdom when it comes to installing an exhaust ?

Thanks,

Ron

[KTL]

For a 85 Carrera you'll need a muffler gasket and two cat. converter/premuffler gaskets.

Pelican's part numbers are here:

Exhaust Gaskets

You'll probably need some new nuts and bolts too. All the bolts are the same size (M8x40). Stainless SAE stuff is good to use. Here's Wil Ferch's good recommendation:

"stock is 8mm x 40 mm carbon steel bolts. I used nearly identical sized 316 stainless bolts and Silicon/Bronze nuts...size 5/16x18 ( 1.5" long under head)...hard to find silicon/bronze in metric. Bonus...the hex head is 1/2" size which is a near perfect match for a 13 mm wrench...no need to worry about metric/US match-up on tools !!
Stainless bolts with Si/Br nuts are just the thing and better than anti-seize or softer copper nuts... "

If the stuff on your car is original, the nuts & bolts in there can be pretty rusty. Penetrating lube (not WD-40) will be needed. Good thing is that the flanges on the exhaust parts are not threaded, so if need be you can cut/grind the head of the nut or bolt off and pop the remaining stud right out.

The oxygen sensor can be a mutha to get out of the cat. too. Put a little antiseize on it when you put it in the new premuffler (don't get the stuff on the tip). Keep in mind that you may want to replace the O2 sensor anyway if it's got a lot of time and miles on it.

Also, those muffler strap screws tend to get frozen in place. More penetrating lube here too. Sometimes the strap just isn't rigid enough to withstand the binding of the frozen screw (even with pen. lube) and will mangle/twist your muffler strap.

Hope this helps.