Another Cougar Newbie

AD26 · 02-11-2011, 10:00 PM

Hi everyone. New to the forum. I've recently picked up a 2001 Cougar with 53000k's on the clock. It's already lowered and sitting on 18s. I'm interested in doing a few basic mods like 2.5" exhaust/extractors, hi-flo cat, k&n pod/panel filter(any preferences?), etc.

I called a few local exhaust shops and they're unable to provide me any headers from the usual suppliers and told me to search the net and make sure they fit a RHD vehicle.

I did better and joined the Ford Forum where it looks like there's a good lot of knowledge being shared

I'm sure I'll be thanking many people here in the future with my noob questions.

I've only found the MSDS headers mentioned here though in my thread picking. Is importing a set of these the only option for us? Not that I'm against it, just shy of a grand is MUCH better than the exhaust shop's offer of fabricating me a pair for 2500.

Also just wondering what the optimal exhaust diameter for the cougar is? I guessed about 2.5" and it seems a few other members of the forum have the same.

Lastly, is there any preference to pod or panel filter?

Thank you all!

**GazzF6** · 02-11-2011, 10:13 PM

Hello and welcome to the forum!

I sure you will get some good information regarding your questions.

K10wN · 02-11-2011, 11:26 PM

Welcome to the forum.

The factory headers have pre-cats in them so well worth upgrading for a bit of extra hp. There's another manufacturer in the UK. They have stainless de-cat header sets listed on ebay for around $400 + shipping from the UK. Being UK, they're made for RHD cars.

Magnaflow makes a direct fit high performance cat. And I don't know about you, but the twin systems look nice, 2.5" systems with 3" outlets either side. Mongoose make these systems direct fit for around $670 + shipping from the UK.

Expect gains of around 20-25hp from doing the entire system through including a free breathing cold air intake. Pod or panel, as long as it's getting it's air from a cold source as there's quite a bit of heat soak under the bonnet of the V6. I like the look of the K&N cold air intake myself over the 57i pod.

Expensive with small gains, but that's the nature of the Cougar. It's not an easy engine to get high power from, and few seem to make or develop parts for a forgotten engine.

One popular upgrade in the US is to swap the engine out for the Duratec 3.0L V6, which with the same upgrades as the 2.5L, yeild higher outputs. Lots of info on these engine swaps on the NECO forums.

Do you have the MTX or ATX box? There's alot more room to work with in the engine bay of the MTX (manual) gearbox models, especially around the air intake.

AD26 · 03-11-2011, 01:17 AM

Thanks for the heads up on the UK gear K10wN. Yeah it's a manual. If I got an auto I might have to share it with the girlfriend.. not the way God intended lol

I'm not really looking to push for the engine transplant. Headers/exhaust, cold air, possibly a reputable ecu piggyback or chip if it's available(don't know much about it yet) and throw in some sound gear and I'll be happy for the rest of my days.

Was just wondering where to look since the exhaust shop asked me to, and I quote, "surf the net, you'll find something". Kind of their job but at least this way I eliminate the finder's fee I'm sure they'd add on.

thearrow · 03-11-2011, 01:56 PM

Welcome aboard and congratulations for getting a Cougar with such low mileage on it, you have done well.

Meantime these are the website you need to save to your "favourites".

Modifying the exhaust is by far and away the best method of obtaining extra horsepower. Start with a 2.5 inch Cat-Back system from Trubendz and you will be amazed at the difference.

http://www.msdsinc.com/ho810.html

http://www.rockauto.com/catalog/rafr...0&model=COUGAR

http://www.mandrelexhaustsystems.com...gar/Categories

You can get a K&N pod filter from Ebay as these fit straight on and you can do it with a screwdriver = 5 h.p. not a lot but it sounds beastly.

The ultimate H.P. gain is the MSDS headers but would recommend you do this last.

Use Rockauto for all your parts and you will save yourself a lot of $$$.

Post some pics if you can...so we can all see your ride..

Cougar2K · 03-11-2011, 06:54 PM

Welcome to the forum AD26.

Congrats on the Cougar purchase.
Must have been a weekend driver only as certainly very low km's for the yr!
Good score.

In any case, MSDS headers is certainly the go for the ultimate HP gain under the circumstances.
However getting the headers here to Oz is the easy part, finding somebody to fit them thereafter is the killer!
Coz bitches whine about how difficult a task it is to work in limited confines in and around the V6 in the engine bay.
At least was the case in my experience!

AD26 · 03-11-2011, 11:44 PM

Thanks for the links thearrow. I've made sure to bookmark the rockauto parts page. 2.5" mandrel bent 304 stainless steel exhaust <-- is this the one you meant?

Yeah Cougar2k, I called the exhaust shop and explained that there were Aus cars fitted with the MSDS headers and he's agreed to do it. When I said that I'd also read the job is a bit of a pain he gave the reply, "that's why we charge labour my friend" lol

thearrow · 04-11-2011, 09:10 AM

Yes this is the one you want stainless steel all the way through and a magnaflow muffler. You won't beleive what it sounds like.

When I put the MSDS headers on mine I had to add another resonator as it was to LOUD for me but man-o-man hello horse power at 4000rpm.

AD26 · 13-11-2011, 02:41 AM

Thanks again everyone, I've put the headers on order. The exhaust I'll put on order next pay. Just checking thearrow, when you say "too loud for you" do you mean I'll be asked questions from the boys in blue every time I go to get cigarettes from the store? or just that you prefer the deeper, mean tone?

thearrow · 13-11-2011, 06:45 PM

I just preferred it as I drive in heavy traffic every day it was just to loud for me. You also have to remember once you have the headers on you won't have pre-catalytic converters which menas that strictly speaking you won't be leagal.

Therefore in the interests of flying under the radar "so to speak" I chose to make it a bit quieter but in the end it is up to you. You exhaust fitter will be able to advise you accordingly.

AD26 · 15-11-2011, 04:43 PM

I spoke to the exhaust guy and he's saying I may need to have the MAF sensor retuned with the install of the headers which he doesn't have the facilities to do. Is this right? My previous experience with headers/exhaust on a car was a 92 toyota paseo lol but it was a drop off and done in 3 hours job.

Guess I'm just chasing information about the install

REDDYZ · 15-11-2011, 09:41 PM

Quote:

Originally Posted by AD26

I spoke to the exhaust guy and he's saying I may need to have the MAF sensor retuned with the install of the headers which he doesn't have the facilities to do. Is this right? My previous experience with headers/exhaust on a car was a 92 toyota paseo lol but it was a drop off and done in 3 hours job.

Guess I'm just chasing information about the install

Thats interesting and never heard. MAF (Mass Air Flow sensor) measures amount of air going in and pumps the required proportions of fuel. It doesn't have any load limitations. ECU will be programmed to calculate the data from all sensors and control fuel management. It is the ability of the fuel pump and the injectors that will decide the outcome. There are other factors involved as well but am just putting in a simple example. Just stick to the plan and get the headers done and you wont be disappointed.

cheers

Yogi

thearrow · 16-11-2011, 09:28 AM

Your exhaust guy is WRONG everything bolts/welds straight on and the ECU will make all the necessary adsjustments as you go roaring off into the sunset.

AD26 · 29-01-2012, 04:35 AM

Hello all. Sorry it's been awhile, I meant to report that I got as far as the K&N CAI kit and half the stereo, serves me right for waiting until the christmas period. Waiting for the rain to go away so I can clean it and take some pics as well.. but I digress, I've been trying to find the SVT throttle body and UIM without much success. Is there another car these can be taken from?

Thanks

REDDYZ · 29-01-2012, 07:58 AM

Try these links from BAT website and see if this helps in your mods. They have listed UIM and LIM but they are super expensive. You can buy a second hand car instead. Do not buy LIM because your car is already fitted with SVT LIM. Check 'SVT Upgrade' thread for more info. These are BAT links:

http://batinc.net/contour.htm
http://208.109.215.220/files/contour.PDF

This website has listed some parts that are not suitable for our Cougars. Just make sure you are bidding on the right ones. You can post a query here, me or someone will direct you.

With headers, if you want the job easy... remove a/c compressor , engine oil filter and alternator you will be laughing. Dropping subframe wont help you anyway. When I said remove a/c compressor degass and remove it. Dont unbolt and let it hang. The aircon manifold hoses are super sensitive and they crack. It happend to many. Use 3/8" long extension and universal joing with 13mm socket, alternator will come off easy. Access points are one from top through the coil pack to access top bolt of alternator and the bottom one is starting from the diff with long extension. Any other way, you will feel 'why on earth you took up this job'.

Keep checking US ebay for SVT UIM and throttle body or UK ebay. Alternately, you can try newcougar.org (sales section)

Incase you happen to find SVT UIM and throttle body and you have a manual gear box you will need throttle cable from automatic trans. Do not buy SVT throttle cable from US as cars are left hand. So, they are made small and won't fit on our Cougars. Just buy a new or second hand throttle cable from ATX cougar locally.

Where are you located anyway?

cheers

baz · 29-01-2012, 04:51 PM

I thought you had a lot of trouble Yogie getting the alternator off a few months ago. do you get the two bolts out from the top? just incase I need to do the job.
Baz

REDDYZ · 29-01-2012, 06:22 PM

Yes Baz, I had trouble getting it off because I had very limited basic tools and I was working at home with car on stands. Eventually I figured out the best and easiest way of taking it out and took pics of it just for future reference.

Thats why I mentioned the easiest way of getting the alternator out. It has only two 13mm bolts one on the top and one at the bottom. Top one has to be done from the top and bottom one from underneath the car. I can post pics if you want.

AD26 · 30-01-2012, 06:11 PM

Thanks for the quick reply. I'll keep checking ebay and yes, I've got the manual gearbox. If I buy a UIM from ebay what are the chances it'll come as a kit? I read the BAT page you linked in and it mentions a few extras I'll need. I'm in Rockhampton, QLD(yay floods!)

REDDYZ · 31-01-2012, 01:35 AM

If you have manual gearbox (MTX) then you need throttle cable from cougar with automatic transmission (ATX). Only 3 ways of getting it. Buy it locally from Ford for $255 (only one available at Melbourne) or get it from wreckers for $75 or $100 depending on their mood to price it or buy it from UK for £27. DO NOT BUY FROM USA as they are LHD and very short in length.

Basically what you need is SVT UIM and SVT throttle body (you already have SVT LIM). These are bolt on upgrades. Other options include 24lbs injectors, SVT cams, SVT MAF will need SVT ECU or custom tune, depending on how far you want to go with mods. I would suggest custom tune as it will give customised options and works better with your CAI and MSDS headers (incase if you consider them). SVT ECU needs PATs keys reprogrammed from Ford. However, if you choose tune, it comes at big price ranging from $900 to $1700. A proper tune will cost $1700 where you will be given a tool (SCT XCal3) that can be used to customise your tune, backup and restore factory tune or switch between 3 custom tunes anytime you like without need of a tune specialist.

If you consider full upgrade including tune, cams and injectors you will need to replace valve springs and few other bits and pieces.

My advise is go for SVT UIM, Throttle body, 2.5" custom exhaust, MSDS headers with Y-Pipe and k&n cold air intake. (if you don't want to spend $$$ on MSDS you can get rid of pre-cats and stock headers are pretty much like MSDS. This doesn't need a tune and won't bother your stock engine and you will be happy with the performance gain. Anything beyond these will need a tune. Don't go with too big exhaust as it will create back pressure issues. What you also has to remember is the UIM on our engines is designed for high torque not for quick acceleration. Instead simple and straight option is to drop in a 3L duratec from Mazda MPV or similar 3L from Ford Taurus.

Feel free to ask any questions...

cheers

AD26 · 31-01-2012, 08:43 AM

Thanks Red, I did read your thread on the SVT UIM and throttle body conversion, hope you're enjoying it after the trouble

While searching ebay for the UIM and throttle body I came across the Fidanza flywheel, reasonably priced and seems easy enough to do. Is it a decent upgrade as well?

The reason I asked about the kit is when I read the newcougar.org site you linked me it mentioned needing UIM, throttle body, throttle body bracket(which seemed to be separate), the throttle cable(ATX from Oz cougar as you mentioned).

I have the MSDS headers and 2.5" mandrel bent stainless steel exhaust already that thearrow linked me, they're sitting in the front room annoying hell out of the girlfriend. It's just with the christmas season just passed and having custom stereo door pods and box built, things are taking longer than expected.

I'm only really looking for bolt on mods. Is there an underdrive pully that fits the cougar?

REDDYZ · 31-01-2012, 09:22 AM

All that trouble was really worth. Just loving my kat now and still doesn't hurt my pocket to feed it. Flywheel is a good option to consider but make sure you change clutch too (with light weight) and also harmonic balancer. Otherwise, you might face odd engine vibrations over 3500rpm. This upgrade will definitely add few horses. I haven't searched for this pulley other than the one mentioned in BAT but am sure there will be one. I will look for them. My clutch is good at the moment. But when it is due to be replaced I will consider all this.

I am sorry I forgot to mention the most important thing which is 'Throttle body bracket'. You need either SVT throttle body bracket or bracket from ATX cougar. Usually you get this bracket when you are buying UIM and throttle body together.

You should get the headers done at first along with exhaust, as they are bolt on and there are not many people out there who like to take up this job.

thearrow · 31-01-2012, 04:44 PM

How can you bear the thought of all that horsepower and noise just sitting in your front room gathering dust.

I am in total agreeance with your G/F on this.

Man get it installed and it will just whet your appetite (and probably hers with some luck

) for more modifications that is.

You won't regret it.

AD26 · 31-01-2012, 05:26 PM

Hah it's not by choice believe me! I'd love to have the headers and exhaust on for more purr, the place I've chosen to do the labour is backlogged from christmas :/

So if I collect:
SVT throttle body
SVT UIM
Oz cougar auto throttle cable
and if the SVT throttle body bracket shoudl be missing an Oz cougar auto throttle body bracket will fill the gap and then I should be all sweet?

I'm keen as mustard to keep the changes happening whilst I'm waiting for the exhaust(booked in for March)

AD26 · 01-02-2012, 08:47 PM

I was wondering if there is anyway to either buy this "new" or someone sources it for you? Tried newcougar.org but no one seems to want to ship to Aus.. which is ridiculous cos I'd be paying the shipping anyway

REDDYZ · 01-02-2012, 08:52 PM

Try this:

https://bongous.com/

You can buy a local US shipping address for $15 and the item can be shipped there and from there it will be shipped down here at an extra cost.

'thearrow' knows about a similar one like this.

AD26 · 01-02-2012, 10:05 PM

Thanks for the tip. Is it really this hard to track down that I have to buy a mailing address instead of using the one I pay for and live in? lol

thearrow · 02-02-2012, 09:31 AM

Typically Yanks think that shipping anything anywhere other than within the USA is some sort of HUGE problem and is all to hard.

I got my UIM and T/B from E-Bay where sellers are a bit more experienced after all they only have to ask at their local post office for the postal rate to Australia like it's not really THAT hard.

There was actually a complete assembly for sale a while ago on Aust. E-Bay (I posted the link on the forum) but at the time no-one was interested.

Keep looking and you will find one sooner or later remember you can do it in stages UIM + T/B + K&N if you can't get everything at the same time.

AD26 · 02-02-2012, 01:36 PM

Thanks arrow, I've actually got a k&n kit on already. Kit was 57i(I think) pod with heat shielding. I just thought with the amount of people carrying them on their cougars here in Aus it wouldn't be this much hassle. I should tell them I'll pay in AU$ since it'd work out to be a bonus for them at the moment

AD26 · 03-02-2012, 08:21 PM

So I sourced the SVT TB and UIM.. not sure if it has the bracket. Hopefully it arrives within 2 weeks. Was the bracket for svt throttle body same as oz atx cougar? or the US atx cougar? or are they the same thing?

REDDYZ · 03-02-2012, 09:28 PM

Am pretty sure ATX bracket is same as SVT bracket. I pulled off throttle cable off ATX cougar by myself and is now on my kat. So, obviously it should be the same. It didn't occur me to grab the bracket along with the cable, went again next day to grab it but someone bought whole engine.

Irrespective of US or OZ cougar, brackets off ATX cougar will be the same.