In this video, Landan provides an overview of the Bassani high-flow catted mid-pipe and Bassani cat back exhaust for an OBS 1992-1996 Ford Bronco. He also shows the process of how to remove the factory mid-pipe and cat back, and install the new Bassani exhaust parts.
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Vehicle Fitment:
- Chassis: OBS Bronco
- Engine: 5.8L
- Year Range: 1992, 1993, 1994, 1995, 1996
Installation Notes:The Bassani mid-pipe will only have one oxygen sensor provision. The 1996 Broncos had three total oxygen sensors. If you own a 1996 Bronco, you will need to purchase two additional sensor bungs and position them correctly, referencing the original mid-pipe. The 1996 Broncos also do not utilize the smog tube that is on the Bassani mid-pipe. You can either cut it flush and weld it or crimp it close. The Bassani mid-pipe comes with an adapter that may or may not be used for your application. Purchasing both the Bassani cat back and mid-pipe will ensure you do not have to worry about fitment issues.
The Bassani cat back also has a slip-fit style connection and will not bolt up to the factory 3-bolt flange. The muffler hanger will need to be fabricated. We ended up using two rubber hangers designed for a 79-04 Mustang to attach to the rods on the factory muffler hanger bracket.
Removal & Installation Instructions
Step 1: Remove The Old Cat Back & Mid-pipe
- Start by disconnecting the negative battery cable.
- Lift the vehicle with a lift or jack and jack stands. Once in the air, take this time to spray a penetrating catalyst such as PB Blaster to all of the attaching points for the mid-pipe and cat back.
- Remove the (3) 9/16" bolts securing the cat back to the mid-pipe.
- Remove the rear tail pipe from the hanger bracket.
- Next, loosen and remove the (2) 1/2" nuts securing the muffler hanger bracket. Be sure to support the muffler before fully removing the last nut.
- Once it is free, snake the cat back out.
- Disconnect the rear oxygen sensor located near the linkage on the transfer case.
- Remove the sensor from the mid-pipe using a 7/8" wrench.
- Disconnect the front oxygen sensor(s). Then remove them from the mid-pipe.
- Starting on the driver's side, loosen and remove the (2) mid-pipe to manifold nuts with an 11/16" deep socket.
- Do the same for the passenger's side. Be sure to support the mid-pipe before removing the last nut.
- Fully remove the mid-pipe from the vehicle.
Step 2: Install Bassani Mid-pipe
- Depending on your year model, you may need to install additional oxygen sensor bungs. Reference your factory mid-pipe for the proper placement.
- We applied a little bit of anti-seize to the socket flanges on the mid-pipe.
- Install the bolts and then position the mid-pipe into place.
- Support the mid-pipe and install the hardware, but leave a little bit of room for adjustment.
- Install the front oxygen sensors and tighten them down, and reconnect each sensor.
- Slide the next section of pipe over the Y section with one of the clamps. This will be the pipe without the catalytic converter.
- Then install the section with the cat converter in place with a clamp.
- Install the rear oxygen sensor and tighten it.
- Rotate the converter pipe so that the sensor is oriented correctly. This will be roughly in the 11:00 position.
- Pass the connection over the transfer case and reconnect it.
Step 3: Install Bassani Cat Back
- Use an exhaust hanger removal tool to remove the factory bracket from the muffler.
- Again, we ended up using two hangers designed for a Mustang.
- Reinstall the bracket back into place and loosely tighten the two nuts.
- Have some kind of support ready and install the muffler over the converter pipe with a clamp.
- Raise the muffler until it looks even. The tabs on the muffler that attach the hanger will need to be situated so that the hangers aren't pitched too far forward.
- Attach the hangers to the tabs on the muffler.
- Now slide the tailpipe section onto the muffler with a clamp.
- Rotate the intermediate pipe until the rest of the piping is even.
- Situate the first clamp and fully tighten. Then tighten the clamp between the intermediate pipe and the converter pipe. Leave the muffler clamps loose for the time being.
- We reused the non-factory hanger bracket and installed it on the frame rail.
- With the tailpipe supported, make sure the tip of the pipe is even, then tighten down the two clamps.
- Fully tighten the nuts that secure the muffler hanger bracket.
- Slide the exhaust tip over the tailpipe and secure it. Make note of the weep hole and ensure it is positioned straight down.
- Look back over the piping and make any needed adjustments.
- Reconnect the negative battery cable, start the truck and check for exhaust leaks.
- After that, you are good to go!
