When I purchased the Bronco, the exhaust was wired in place with a couple of coat hangers and the end of the Y-Pipe rotted out so someone cut off the rotten part and jammed a aftermarket muffler on the end. The problem was that without a tailpipe all of the exhaust fumes where coming up into the drivers compartment which made me very nauseous while waiting at stop lights.
The first thing to do was to replace the Y-Pipe. So a couple of days ahead of time I sprayed all of the exhaust manifold bolts with Liquid Wrench before taking a breaker bar to them. Wouldn't you know it the very last stud on the passenger side snapped! I found this neat device called Clamp-A-Stud which prevented me from having to drill out the snapped stud. Here is what a Clamp-A-Stud looks like when it is installed:
I had to special order the Y-Pipe as no local parts stores were able to get it. When it arrived I found out that the Y-Pipe didn't align with the exhaust manifolds, it was a half inch off. I tried to bend the pipe but to no avail so finally I took a cutoff wheel to it and used a union to extend it a half inch. See picture below:
Now the drivers side exhaust manifold bolted right up to the Y-Pipe:
Here is a picture of how the Y-Pipe connects to the muffler:
Here is a picture of the generic Walker muffler I used:
This is how the tailpipe fit. I had to drill a couple of holes for mounting hanging brackets. Notice how I used a hanging bracket to keep the parking brake cable form touching the exhaust:
Here is how I bolted the end of the tailpipe to the frame:
