For Ford Lightning owners seeking to upgrade their exhaust systems, the Bassani exhaust system has long been a popular choice for its performance and durability. However, installation of such systems often requires a nuanced understanding of the components, tools, and steps involved. This article compiles firsthand installation notes, technical observations, and user insights from a detailed community post, offering a comprehensive reference for those undertaking a Bassani exhaust installation.
The following guide draws from a single, authoritative source—a detailed user account from an online forum—covering everything from unboxing and component inspection to installation best practices and common issues. These insights are valuable not only for their practical advice but also for their emphasis on customization and adaptability, which are essential when working with aftermarket parts that may not always align perfectly with factory specifications.
Unboxing and Component Overview
When unboxing a Bassani exhaust system, users can expect a structured and clearly organized delivery. Inside the packaging, there are three primary components: two mufflers and an X-pipe. These are housed in individual boxes for protection, while fasteners and hardware are stored in small, labeled baggies. Additionally, the box includes a disclaimer sheet with warranty information and a two-page set of instructions that combine text with visual aids.
Users should note that the clamps are often loosely placed within the box and are at risk of being misplaced during unpacking. It is advisable to locate and set aside these components early in the process to avoid potential confusion later.
Another key detail is the change in sticker design from the previous version, which used silver letter cutouts. The new design, while functional, may not align with all aesthetic preferences, particularly on surfaces like glass. Nonetheless, the stickers are typically considered a nice touch and a point of pride among users.
The 2.5-inch spacers included in the package have been identified as problematic by some users. These spacers, or the bolts that fit into them, may be incompatible with the frame rail due to either being too long or too short. This discrepancy necessitates manual adjustment—either by cutting down the spacers or replacing them with alternative materials such as stacked washers. This customization is an important step for ensuring proper fitment and should be approached with care to avoid misalignment or mechanical stress.
Pre-Installation Preparation and Component Removal
Before beginning the installation, it is crucial to understand the condition of the existing exhaust system. Users with higher mileage vehicles may find the stock muffler difficult to remove. One user reported that their stock muffler had to be removed using heat and a mallet, as it had become almost permanently attached after prior replacements. This process can be time-consuming and labor-intensive, with one user estimating a half-hour just to remove the original component.
In some cases, the stock muffler may not be salvageable. A user noted that repeated impacts with the mallet rendered their old muffler unsuitable for reinstallation. This highlights the importance of planning for potential disposal or alternative reuse of the original part before initiating the installation.
Installation Steps and Key Considerations
The installation of the Bassani exhaust system is a multi-step process that requires attention to detail and careful execution. Below are the key steps and considerations based on the user’s experience and advice:
Disposal of Old Components:
The original rubber hangar donuts are no longer needed and can be discarded. This simplifies the installation process and reduces the number of components that must be managed.Orientation of New Hangars:
The user emphasizes the importance of following the photo instructions closely when installing the new hangars. These components are not symmetrical and can be easily installed backward if not carefully inspected. The user admits that even experienced individuals can make mistakes at unusual hours, such as 3 AM.Nut and Bolt Management:
A common oversight in such projects is the loss of small components like nuts and bolts. The user reminds readers to be vigilant and keep track of these parts throughout the installation process.Handling of Lowered Vehicles:
If the vehicle has been lowered (a common modification among Ford Lightning enthusiasts), special attention must be given to one of the hangar mounting points. The user advises consulting other community members for advice on adapting the installation to suit the vehicle's specific configuration.Spacer Adjustments:
As previously mentioned, the 2.5-inch spacers included with the Bassani system may not fit correctly. The user recommends cutting the spacers to size using a pipe cutter or replacing them with alternative materials such as stacked washers. This step is crucial for ensuring that the bolts have enough threading above the frame rail.Avoiding Premature Tightening:
One of the most important pieces of advice is to refrain from tightening any bolts until the entire exhaust system is in place. This allows for proper alignment and adjustment of all components before securing them in position. Premature tightening can lead to misalignment, uneven stress, and potential damage to the system.Clearance and Access Issues:
If the installation is obstructed by components such as a lift arm, it may be necessary to temporarily lower the vehicle, reposition the arm, and then raise it again. This step ensures that the mufflers can be properly aligned and installed without interference.Clamp Design Changes:
The user notes that Bassani has changed the design of the clamps used in their systems. Instead of providing U-bolts, the system now requires users to source their own clamping solution. The user suggests that tack-welding may be appropriate for highly modified vehicles to ensure a secure and stable installation.
Post-Installation Observations and Performance
After installation, users reported noticeable changes in both sound and performance. The exhaust system was described as producing a “glasspacky” sound when backing down in third gear, though without the typical popping associated with glasspacks. This unique acoustic profile was noted as a subtle but distinct improvement, with one user describing it as a “nice rumbling pop.”
Another user observed that the system was initially louder before it was “broken in.” This suggests that the sound may settle or mellow over time, which is not uncommon for new exhaust systems. The overall consensus among users is that the Bassani system provides a balanced and distinctive sound that enhances the character of the Ford Lightning without being overly aggressive.
In terms of visual presentation, the system was praised for its clean and professional appearance. The X-pipe, in particular, was highlighted for its construction and design, which contributes to both performance and aesthetics.
Conclusion
The Bassani exhaust system represents a significant upgrade for Ford Lightning owners seeking enhanced performance and a distinctive sound. While the installation process requires careful attention to detail and some degree of customization, the rewards are well worth the effort. The user insights compiled in this guide offer a valuable roadmap for those undertaking the installation, covering everything from unboxing and component inspection to step-by-step installation tips and post-installation performance observations.
The key takeaway is that while the manufacturer-provided instructions are useful, they may not cover every possible scenario—especially for modified or customized vehicles. Community knowledge, such as that shared in the source material, is an essential resource for filling in the gaps and ensuring a successful outcome.
For users who are new to such projects, it is advisable to proceed methodically, keep all components organized, and consult with experienced installers or online forums when necessary. With the right approach, the Bassani exhaust system can deliver a satisfying and transformative upgrade for any Ford Lightning.