Upgrading your Ford Mustang Shelby GT350 with a Roush exhaust system is one of the most effective ways to boost both the performance and the auditory presence of this iconic muscle car. The Roush exhaust is engineered to deliver a deep, aggressive tone that complements the GT350’s naturally aspirated V8 engine, while also enhancing exhaust flow for improved horsepower and throttle response. This comprehensive guide will walk you through the step-by-step installation process, provide detailed tips to ensure a smooth upgrade, and explain the numerous benefits you can expect from equipping your Shelby with a Roush exhaust system.

Why Choose a Roush Exhaust for Your Shelby GT350?

Roush Performance is a renowned name in the automotive aftermarket industry, specializing in high-quality performance parts for Ford vehicles. Their exhaust systems are designed specifically to improve the sound, performance, and aesthetics of the Mustang Shelby GT350. Here are some of the key reasons why a Roush exhaust is an excellent upgrade choice:

  • Precision Engineering: Roush exhausts are crafted using high-grade stainless steel and precision welding techniques to ensure durability and corrosion resistance.
  • Optimized Exhaust Flow: The system features mandrel-bent piping that reduces backpressure, allowing the engine to breathe more freely and produce more power.
  • Aggressive Sound Profile: Designed to enhance the GT350’s naturally aspirated V8 growl, the Roush exhaust adds a throaty, muscular tone without being overly loud or droning at cruising speeds.
  • Direct Fit Installation: The kit is designed for a bolt-on installation with no cutting or welding required, making it accessible to both enthusiasts and professional installers.
  • Customizable Sound Options: Certain Roush models include adjustable valves or electronic sound management, allowing drivers to switch between aggressive and mellow exhaust notes.

Tools and Parts Required for Installation

Before beginning your installation, gather the following tools and parts to ensure a smooth and efficient process:

  • Roush Exhaust System Kit: Confirm compatibility with your 2015-2020 Shelby GT350 model year.
  • Socket Set and Ratchet: Various socket sizes will be needed, typically 13mm, 15mm, and 18mm sockets.
  • Torque Wrench: For tightening bolts to manufacturer-specified torque settings.
  • Flathead and Phillips Screwdrivers: Useful for clamps and brackets.
  • Jack and Jack Stands or a Car Lift: Safely elevates the vehicle to access the exhaust system underneath.
  • WD-40 or Penetrating Oil: Helps loosen rusted or seized bolts and clamps.
  • Rubber Mallet: To gently persuade exhaust components into place without damaging flanges.
  • Safety Gloves and Glasses: Essential for protecting your hands and eyes during installation.
  • Exhaust Sealer or Anti-Seize Compound: Optional, but recommended to prevent leaks and corrosion on bolts.

Preparation and Safety Precautions

Proper preparation is crucial before starting the installation to avoid injury and ensure the best results:

  • Park on a Level Surface: A flat, stable surface prevents the vehicle from shifting while lifted.
  • Allow the Engine to Cool: Exhaust components can become extremely hot. Wait at least two hours after driving before starting the installation.
  • Secure the Vehicle: Use a jack to lift the front or rear of the Mustang, depending on access points, and place jack stands securely under the frame or designated lift points.
  • Wear Protective Gear: Gloves protect your hands from sharp edges and hot surfaces; safety glasses shield your eyes from debris.
  • Disconnect the Battery (Optional): For additional safety, consider disconnecting the negative battery terminal to prevent accidental electrical shorts.

Step-by-Step Guide to Removing the Factory Exhaust

Removing the stock exhaust from your Shelby GT350 requires patience and attention to detail to avoid damaging sensitive components:

  1. Apply Penetrating Oil: Spray WD-40 or a similar penetrating oil on all exhaust bolts, nuts, and clamps. Allow it to soak for 10-15 minutes to loosen rust and corrosion.
  2. Locate Exhaust Mounting Points: The factory exhaust is secured with hangers, clamps, and bolts at the catalytic converters, mid-pipe, and muffler sections.
  3. Remove Exhaust Clamps and Bolts: Using the appropriate socket sizes, loosen and remove all fasteners connecting the exhaust components. Keep these bolts in case they are reusable.
  4. Detach Exhaust Hangers: Carefully pry the rubber hangers off the metal pegs using a pry tool or flathead screwdriver. Applying lubricant can ease this step.
  5. Lower the Exhaust: Gently wiggle and lower the exhaust system from under the car. Assistance may be needed due to the weight and size of the components.
  6. Inspect Underneath: Take this opportunity to inspect the undercarriage for rust or damage and clean the exhaust flange mating surfaces.

Installing the Roush Exhaust System

With the factory system removed, you are ready to install your new Roush exhaust. Follow these steps carefully to ensure correct fitment and performance:

  1. Compare Components: Lay out the Roush exhaust parts side-by-side with the old system to familiarize yourself with each piece and confirm completeness.
  2. Pre-fit the Sections: Align the new exhaust pipes and mufflers underneath the vehicle to check fitment. This helps identify potential clearance issues.
  3. Install Exhaust Hangers: Attach new or existing rubber hangers to the Roush exhaust components before mounting.
  4. Connect Mid-Pipe and Mufflers: Position the mid-pipe and muffler sections at their respective mounting points. Insert the exhaust hangers into their rubber mounts.
  5. Hand-Tighten Clamps and Bolts: Use the clamps provided in the kit to loosely connect the exhaust pipes. Avoid fully tightening until all components are in place and aligned.
  6. Check Alignment and Clearances: Ensure the exhaust tips are centered within the rear valance cutouts and that no pipes touch the underbody or suspension components.
  7. Tighten All Fasteners: Using a torque wrench, tighten clamps and bolts to the manufacturer’s recommended specifications to prevent leaks and rattles.
  8. Apply Anti-Seize Compound: If desired, apply anti-seize compound to bolts and fasteners to facilitate future removal.

Post-Installation Steps and Inspection

After the exhaust system is installed, it’s important to perform thorough checks before hitting the road:

  • Lower the Vehicle: Carefully remove the jack stands and lower your Mustang back to the ground.
  • Visual Inspection: Check for proper clearance around the exhaust pipes, ensuring they do not contact brake lines, fuel lines, or suspension parts.
  • Start the Engine: Listen closely for any exhaust leaks, rattles, or unusual noises. Small leaks may sound like a ticking or hissing sound near joints.
  • Retighten as Needed: If you detect leaks or loose fittings, re-tighten clamps and bolts accordingly.
  • Test Drive: Take your Shelby GT350 for a short drive to evaluate throttle response, sound quality, and overall performance.
  • Final Check: After the test drive, inspect the exhaust system again for any signs of shifting or loosened hardware.

Additional Tips for a Successful Installation

  • Work with a Partner: Having an extra set of hands can make handling heavy exhaust components safer and easier.
  • Use a Torque Wrench: Proper torque ensures bolts are neither too loose nor overtightened, preventing leaks and damage.
  • Keep the Work Area Clean: Dirt and debris can cause issues during installation; wipe down mating surfaces before assembly.
  • Consider Professional Help: If you’re uncomfortable working under the vehicle or lack necessary tools, professional installation can guarantee optimal results.
  • Check Local Regulations: Aftermarket exhaust systems may affect emissions compliance and sound regulations. Verify that your Roush exhaust is street-legal in your area.

Benefits of Installing a Roush Exhaust on Your Shelby GT350

Installing a Roush exhaust system offers a range of tangible benefits that enhance both driving enjoyment and vehicle performance:

  • Enhanced Engine Sound: The Roush system amplifies the GT350’s signature V8 roar, delivering a bold and aggressive exhaust note that turns heads.
  • Improved Exhaust Flow: Mandrel-bent piping and optimized muffler design reduce backpressure, allowing the engine to expel exhaust gases more efficiently.
  • Increased Horsepower and Torque: Better exhaust flow often translates into measurable gains in horsepower and torque, improving acceleration and overall performance.
  • Better Throttle Response: With reduced exhaust restrictions, the engine reacts more quickly to throttle inputs, enhancing driving dynamics.
  • Weight Reduction: Many Roush exhaust systems are lighter than factory components, contributing to improved handling and fuel efficiency.
  • Custom Sound Profiles: Some Roush systems feature adjustable valves or electronic controls, allowing you to tune the exhaust note to your preference.
  • Visual Appeal: Polished stainless steel tips and sleek pipe design add an aggressive and refined look to the rear of your Mustang.
  • Durability and Longevity: High-quality materials resist corrosion and wear, ensuring your exhaust system performs well for years to come.

Maintaining Your Roush Exhaust System

Proper maintenance will help preserve the performance and appearance of your Roush exhaust:

  • Regular Cleaning: Use mild soap and water to clean exhaust tips and visible pipes, removing grime and preventing discoloration.
  • Inspect for Damage: Periodically check for dents, cracks, or loose brackets that may affect performance or cause noise.
  • Address Leaks Promptly: If you notice unusual sounds or exhaust smells, inspect for leaks and repair or tighten connections as needed.
  • Protect from Corrosion: In winter climates, consider rinsing the undercarriage to remove road salt that can accelerate rust.

Conclusion

Installing a Roush exhaust on your Ford Mustang Shelby GT350 is a rewarding upgrade that delivers both audible and performance benefits. By following this detailed installation guide, you can confidently replace your factory exhaust with a system that enhances your car’s aggressive sound, increases power output, and elevates your driving experience. Whether you choose to install it yourself or enlist professional assistance, the result will be a Shelby GT350 that not only looks iconic but sounds and performs like a true muscle car legend on the road.

For more information on Roush performance parts and compatible exhaust models, visit the official Roush Performance website. Additionally, consider consulting your local Mustang clubs or forums for tips and shared experiences from fellow Shelby enthusiasts.