Removing & Replacing the Back Box....

[rhaines]

Although this may not be the best description though it might be handy for some....

Went down to Hampshire with Scot very at silly O'clock on Saturday morning to pick up the Mongoose exhaust. I was going to pay someone to fit it but Scot (turning veryu quickly into my technical guru...) persuaded me that it would not be to difficult to fit it ourselves so.....

On the way home we popped into Octagon Toyota in Reading and spoke to Paul (might have been Peter) on the parts desk who was amazing, gave us 30 - 40 minutes of his time discussing a number of issues and finding the right sized fire ring for the job (I hadf to carry the whole Mongoose backbox, twin 3" exits into through the showroom and to the desk). Best to buy a couple of these as they're cheap and always better to have a spare if you make a mistake !!

When we got back to Oxford simply reversed the car up onto the blocks and secured the front wheel (always gotta be safe)...

The exhaust system is held on by 6 bolts, two either side of the main back box, two to the cat/de-cat pipe and two from the back-box to the de-cat pipe, we undid them in the following order looking at the car from the rear...

1) Left main back box bolt.

2) Top and Bottom de-cat pipe bolts

3) Right main back box bolt

Although undoing the main bolts leave the current back box hangin on these bolts while undoing the last two bolts which hang connect the back box to the cat/de-cat pipe if you have them....

Once all other bolts are out of the way you'll need one person to support the back box and lift it slightly to take the pressure off and one person to remove the two remaining bolts (main bolts left in to support the back box), then simply drop the box out of the way....

Looking at the fit of the new box you may need to use an angle grinder to remove the section where the bolts connected the stock back box to the cat/de-cat pipe, take it as short as possible and smooth over with a file....

Now for the easy part....

If you've got hold aof a second hand back-box am gussing most of you would polish/clean it before fitting anyway but for completeness next step is to clean the exhaust :P

Before starting to re-fit the new back box use a wire brush to clean the surfaces of the exiosting manifold and surfaces that will be joined together...

Quick next step is to spread the exhaust gunm (sorry forgot name) liberally on the join from the cat/de-cat pipe which will be joining to the exhaust while you put the new back box into position, if you leave it a couple of minutes it get's stickier and it's easier to keep the fire ring in place.

Place the Fire ring around the hole from the cat/de-cat pipe, you need this to fit properly around the hole so make sure it sticks in place before putting the back box in place, it doesn't have to be super sticky but sticky enough that it will hold semi firm while tightening the bolts...

We found it easier to have two people, one person sliding the exhaust under the car on his/her lap and the second to bolt the main left & right back box bolts in very loosely to support the back box during the fitting process...

Once the back box is hanging get one of the smaller bolts and connect the back box to the cat/de-cat pipe, don't do this tightly, just enough that the nut will stay on the bolt and do the same for the other bolt. Once the bolts are on loosly tighten them gradually, a little pressue on top then bottom and repeat until tight so the pressue is the same top and bottom and there is less chance of the ring moving while it's being tightened up...

Next step is to tighten the main left and right support bolts for the back box and check all bolts involved have been tightened as much as you can....

Final step is to turn the engine on and leave the engine running for a while so it can heat up (after 10 mins take it for a quick spin to really heat the engine up).

Once you've stopped the engine check the gum is running a little (it goes goey to fill all the gaps and smooth over lightly with a cloth and let it set...

After you've done that and the gum has set take your car take your roof off (t-bar's only :P) and enjoy the amazing sound which the Mongoose makes....

My car is now accelerating a lot smoother all the way through the rev ranges and is sounding a lot, lot better (very loud during heavy acceleration and quiet at running speed).....

Scot followed me home last night and was sure he saw a little flame come from the exhaust under heavy breaking from just under red line (will try and repeat on track at combe)....

Final optional step.....

I bought some colour coded paint from Halfords and decided to respray the blackish guard behind the back box so today masked off the exhaust and bumpers (all areas around guard) and sprayed the surround).

Back of the car looks a lot better and sounds great.

I should have some photo's to go with this post tomorrow...

As long as you have a good socket set, the correct fire rings, some exhaust gum and a patient friend :), oh and a couple of hours you should have no problems replacing your exhaust....

I have to wait till Monday for the rear light conversion but will take better photo's of the steps required.....