I just ordered a milltek exhaust for my 05 MCS.... just wondering if anyone wanted to share their tips in installing this new exhaust system. Thanks.

 

I did mine, just follow the how to and you'll be set!

 

ditto

I had issues with the removal of the flange bolts between the stock cat back and the cat flange. Had to cut one off and replaced both with new ones. no biggie. Also used washers as spacers on the rear hangers for the pipes not to vibrate against the heatshield, also no biggie.

Do a search. there are plenty of experiences around with this install.

Finally, as with any DIY mod "Patience is a Virtue".

Good Luck!, you will love the Milltek.

 

take the extra step to "dry fit" the system first and mark all the fittings - installation is a breeze

 

I'm going to follow this thread too...

This how-to you all refer to, it comes with the Milltek or was put out by Randy Webb or someone?

 

OHHHHH!!!!!!! I almost forgot! Get some antiseeze, I like PJ's Blaster or whatever, and spray it on those nuts and bolts that attach to the CAT, you'll be able to break them loose with a breaker bar if you do this, otherwise, depending on the car, u might have to cut them....

HOW TO REFERENCE

https://www.northamericanmotoring.co...ead.php?t=3955

 

I just put mine in a couple of weeks ago and really only ran into one problem. I read over on MINI2 that few people has this same issue as well, although some did not. The bracket hangers welded on the mufflers appears to be a little short causing the mufflers to touch the underside of the car. This height issue also manifested itself in the tips touching the valance.

To fix this problem I put some spacers under the rubber bracket hangers which dropped it down about 3/8 of inch. Then everything fit correctly.

You are going to certainly enjoy this exhaust.

 

My exhaust barely touches the valence, not even enough to burn it. Nothing to worry about, you can't physically see it touching it without putting your head on the exhaust pipes.

It's not a problem unless you have an Aero Kit

 

The Milltek is a pretty easy DIY, especially if you can get your S up on a hoist.

In reference to the touching of the rear valence, mine does it too - one other Aussie with the Milltek has trimmed the valence lip (2mm).

Have fun

 

Biggest thing is to not drop the stock exhaust on your head as you unbolt it... That thing is heavy

 

It really helps to put a jack under the old exhaust as you are loosening it. As mentioned above, it prevents it from coming crashing to the ground, it is fairly heavy.

 

A box works!

 

I'll agree with the others about using washers to make sure that the cans don't vibrate against the heat shield. There is a VERY good reason why. Until I put in the washers to solve the contact with the heat shield, the vibration would cause the nuts at the cat to work their way loose. NOT a good thing. It happened repeatedly until I stopped the contact via the washers. Lock washers, lock nuts, thread lock, nothing worked. All would work their way off. A few bucks worth of washers (ss) and I haven't had the pipe work it's way loose since. You get a little more valence clearance to boot (or you can use this to solve a valence clearance problem directly).

One side effect of the cat/Milltek working its way loose is that a gap opens at the connection. The gasket then loses the fill, and it will never seal again. The gasket is a specialized one. I visited most auto parts stores around town and no one had a direct replacement. NAPA sells about 2 jillion gaskets, and only one came close.

The gasket inconvenience pales in comparison to the safety hazard posed to your exhaust system parting near the front of the car.

I was very unhappy with my Milltek until this situation was resolved. you can read my posts in Webb Motorsports (lengthy) Milltek forum thread.

I'm not sure if the "new" hanger orientation has any impact on this or not.