Active exhaust Harness failure

[nickhill]

Hey, my 2021 PP1 GT has the factory Active exhaust and I’m currently on my 3rd sliced harness on the passenger side. I’ve tried adjusting the exhaust to sit lower and the harness in different positions but am constantly plagued with the body cutting it. My next option is going to be notching the flap of pinch weld…any recommendations so I don’t have to cut up my car?

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[NGOT8R]

Cut about 1” off of your exhaust pipes where they meet the x or h-pipe. This will allow you to slide the exhaust system forward to create enough clearance between the actuator harness and the pinch weld.

 

[SheepDog]

Hey, my 2021 PP1 GT has the factory Active exhaust and I’m currently on my 3rd sliced harness on the passenger side. I’ve tried adjusting the exhaust to sit lower and the harness in different positions but am constantly plagued with the body cutting it. My next option is going to be notching the flap of pinch weld…any recommendations so I don’t have to cut up my car?

The solution is not to lower the exhaust. The solution is to loosen the clamps at the resonator, and shove the entire exhaust forward as far as it will go.

 

[junits15]

The solution is not to lower the exhaust. The solution is to loosen the clamps at the resonator, and shove the entire exhaust forward as far as it will go.

This is the answer, you may have to cut some off of the exhaust as @NGOT8R said too.

I had to do this twice, its a bad design.

 

[John S]

It's a mass produced Mustang with sloppy build quality, I'm sure no one's feelings would be hurt by a BFH on the pinch weld.

 

[SheepDog]

There’s enough “slack” in the butt clamps between the resonator and the “S” pipes to push the exhaust all the way to the ends of the hangers. You will easily get 3” forward. No cutting or smashing required.

 

[GTP]

I put good quality edge guard on my pinch weld as soon as I heard of this issue. It's still there.

I had not heard of the push the assemblies forward method.

 

[WD Pro]

If it helps, I shortened my active exhaust with H pipe by about 16mm total when I fitted the H after my standard system had started to rub.

I made the ‘perfect’ cut, then shortened the cut and the front of the H pipe by about 8mm each.

Right side loom off the standard system had just started to rub :

Before (standard system / standard fitment on the right) v after (modified with H) :

Loom clearance after the mod :

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[RescueLt]

I put good quality edge guard on my pinch weld as soon as I heard of this issue. It's still there.

I had not heard of the push the assemblies forward method.

Did the same, as well as moved the pipes forward slightly. No more issues.

 

[Cobra Jet]

I had posted this thread a while back to help with the pinch weld issue. It should help out in many situations where the AE harness is being damaged on or near the body sheet metal.

https://www.mustang6g.com/forums/threads/prevent-ae-active-exhaust-harness-chafing-damages.175530/

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