5 Things to Do Before Installing a New Exhaust System

Your new Thermal R&D Performance exhaust has just arrived - shining bright, looking flawless, and you can’t wait to hear that rumble.

Most of our systems are direct bolt-on replacements with no cutting or welding required, so installing an exhaust in your driveway or garage is a DIY project. However, preparation is the key to a smooth install. Here are 5 things you need to do before getting under your car.

1. Lubricate Your Hardware Before You Start

Before beginning your installation, spray all of the factory exhaust bolts, nuts, and clamps with a quality lubricant or rust penetrant, such as WD-40 or a similar product. This helps loosen hardware that’s been exposed to heat, moisture, and road debris, making removal much easier and reducing the chance of seized or broken bolts. For the best results, apply it a few hours before you begin.

2. Gather the Right Tools

There is nothing worse than getting your old factory exhaust half-off, only to realize you are missing a tool. Ensure you have:

• A high-quality floor jack and heavy-duty jack stands (or access to a lift).
• A 3/8" or 1/2" drive socket set with deep well sockets and extensions.
• Exhaust hanger removal pliers (these make removing the rubber isolators incredibly easy).
• Safety glasses that fit snugly to your face (falling rust dust is a guarantee) and gloves.

3. Inspect the Rubber Hangers

Most exhaust systems are suspended under the car by rubber isolator mounts. Over time, these may dry rot, stretch, and crack. Inspect them while you are spraying your bolts. If they look worn, have replacements ready before you begin.

4. Check for Clearances

Before lifting the car, take a look at how the factory exhaust routes around the suspension, axles, and frame. Take a few photos with your phone. This gives you a great visual reference for exactly how your exhaust is routed, and you can refer back to the images at any point in the project.

5. Clean the Flanges

Once the old exhaust is off, don't just bolt the new one right up. Take a wire brush or some emery cloth and clean the mating surface of the factory catalytic converter flange. Ensuring this surface is clean and flat will give you a leak-free seal when you install your new hardware and gaskets.

Enjoy the Sound of Your New Thermal R&D Exhaust

Lastly, remember to take your time, leave all clamps slightly loose until the entire system is perfectly aligned, and tighten from front to back. And if you run into issues, contact us at (661) 591-4142. We're here to help you get the best sound out of your ride!

We make exhaust systems for a wide variety of cars and trucks, including popular enthusiast models and smaller niche vehicles other companies won't touch. Our systems feature True Helmholtz Technology, are built in the U.S.A. by our team of talented fabricators and finishers, and are backed by a lifetime warranty. Upgrade your exhaust today!