Do you know how to loosen 8 bolts? If so, you can do this install in less than 2 hours. My first time took me about an hour and half. BE SURE YOU HAVE A SWIVEL AND A 12" EXTENSION AND SOME PB BLASTER OR LIQUID WRENCH.
Prep parts:
-Get a 12" extension (put 2 together if you have to) ($5)
-a ratchet (unless you have an impact wrench) ($3-$20)
-a swivel ($5-$200)
-a 15mm deepwell socket (<$1)
-PB Blaster/Liquid Wrench (?)
-2 jack stands ($20-$100)
-a passenger side manifold gasket (get from your local Ford parts dealer) (~$10)
-a jack ($20-$200)
-2 ramps ($20-$70). Oh, you might want a flashlight ($0-$200) too to make those manifold bolts easier to see.
Total Parts Cost: $84-$806 (unless you already have some of the parts, which you probably do)
1) Let the car cool down for at least 1 hour (I know some guys on here that have permanent scars from exhaust burns...trust me, let it cool)
2) Since it is a rear wheel drive car (back wheels locked by first gear), back the car onto some stands. Now jack up the front end and place jack stands on the axels.
3) Go change into some old nasty clothes that you don't mind getting dirty.
4) Spray some PB Blaster or Liquid Wrench and let sit for about 20 minutes. WARNING: THIS STUFF DOES DRIP AND SPLATTER AND WILL STAIN YOUR CLOTHES!
5) Unbolt the 4 bolts where the mid-pipe and cat-back join (if you have an impact wrench this should take LITERALLY less than a minute).
6) Using the extension, unbolt the 2 driver-side bolts where the manifold meets the mid-pipe.
7) Using the extension, unbolt the furthest out bolt on the passenger side (where the manifold meets the mid-pipe).
8) Using the swivel and the extension, unbolt the inner-most bolt on the passenger side (again, where the manifold meets the mid-pipe).
9) Carefully disconnect all of the o2 sensors and drop the mid-pipe.
10) Unscrew the o2 sensors and screw them into the new mid-pipe.
11) Place the new manifold gasket in (on the passenger side) and bolt up the manifold side of the mid-pipe first, in the same order you took them off (driver-side, outter-most passenger, inner-most passgener). IMPORTANT: LEAVE THESE BOLTS A LITTLE LOOSE FOR SLACK!
12) Bolt up the mid-pipe to the catback and tighten thoroughly.
13) Tighten manifold-mid-pipe bolts.
14) Connect the o2 sensors; if they don't reach, buy an extender from your local automotive store.
15) IMPORTANT: CLEAR ALL TOOLS FROM THE AREA UNDERNEATH THE CAR!
16) Jack the car back up off of the jack stands and lower the car.
17) Drive the car off of the ramps and voila! You're done!
Note: if you have an impact wrench it will cut the install in half...those things work wonders!