Has anyone else installed Magnaflow Ypipe part# 23353 on their Windstar and did the rear upstream O2 Sensor come into contact with the steering rack metal when fully tightened up? If so and you left it that way has the O2 sensor "been ok" like that? Does anyone think this would cause a problem? I just installed my Ypipe and I'm hesitant to proceed with the rest of my work and leave it the way it is cause I'm worried the O2 Sensor is gonna get damaged when the engine moves on startup or during accel/decel.

What do ya'll think?
http://www.thinkrolland.com/images/externallylinked/95WindstarMagnaFlowYpipeO2Sen-0009-smaller.jpg

Are you sure all fasteners are tight and torqued to specs? Does the rest of the piping looks to be where it should be (Cats, Muffler, Resonator) and not touchingany of the undercarriage?
If so, I would call MagnaFlow so they can explain to me how is this supposed to work! I would like to see at least three inches of clearance between components as the engine rocks forward and backward under accelleration and de-celleration. That O2 sensor is not going to last where its sitting right now!

Yeah I have contacted magnaflow about it today Ed. I also emailed the reseller I bought it from too. Magnaflow says they are doing an investigation to check the design specs, but to do so properly means getting a vehicle in there to do it so it isn't gonna be quick.

Anyone that is curious or wants to help HERE'S A VIDEO of the O2 Sensor moving as I rev engine and shift gears from P to R to N to D 2 1 and then 1 2 D N then R then P again:

Video LINK of O2 Sensor Moving with MagnaFlow Ypipe in my 95 Windstar (http://www.thinkrolland.com/images/externallylinked/Windstar95-3.8LEngMagnaFlowYpipeO2Sensor.wmv)

ALSO KEEP IN MIND THAT VIDEO WAS TAKE WITHOUT THE CAT-BACK EXHAUST HOOKED UP AT ALL. Don't think it'll make much difference, but good to state it.

It kinda looks like it would be ok all times except when I'm first shifted into Reverse which pushes the O2 forward. All Drive gears seem to push the O2 away from the rack housing. What do ya'll think?

That's really a high quality video. What camera are you using?

Have you replaced the engine/tranny mounts? That looks like a great deal of movement to me. And it could be that the engine is not where it should be ... because of a broken mount.

That sensor may have a longer body than on my '99's ... but I need to take a look before really misleading you. This will take a few days I'm afraid.

I don't blame you - I wouldn't want to leave it there either.

That's really a high quality video. What camera are you using?

Have you replaced the engine/tranny mounts? That looks like a great deal of movement to me. And it could be that the engine is not where it should be ... because of a broken mount.

That sensor may have a longer body than on my '99's ... but I need to take a look before really misleading you. This will take a few days I'm afraid.

I don't actually know about the tranny mounts, but I do know both engine mounts were replaced when my tranny was rebuilt 20k ago. I thought the engine mounts and tranny mounts were synonymous for some reason... i guess i thought that during the tranny rebuild tranny mounts would've been suggested for replacement and not just the engine mounts.

Video/Photos: I'm just good with getting the right shot. Its just a 3.2MP Canon S1 IS, but I find this is the best camera I've ever used. Its somewhere between average consumer and SLR (professional) style cameras cause it has a lot of manual config settings. The key to a good shot is good lighting though and I had a flourescent hand light just near the camera. Set the positioning and do some contortion acts to get out from under the van and presto. Then I clipped out all the useless footage with Windows Movie Maker and produced a pretty well compressed high quality WMV which is half the compression size as an AVI which is what the camera outputs. I also maintained the original video aspect ratio and resolution in the WMV output. Takes some experimenting to get it right, but when you find the sweet spot its golden.

NOBODY ELSE HAS INSTALLED THIS PIPE? damn. lol

From what I can tell from the link below I've replaced the two main most mounts (20k ago) that would absorb the forward and backward motions of the engine shifting/moving. What I don't believe was replaced was the item indicated by #4 at that link "4) Mount insulator Trans side (http://www.parts.com/oemcatalog/index.cfm?action=getJointLocator&siteid=2&chapter=&Sectionids=0,2453&groupid=51840&subgroupid=10046&componentid=5021&makeid=10&model=Windstar&year=1995&graphicID=MT95210&callout=4&catalogid=2&displayCatalogid=0)" - Still don't think it would be restricting much forward/backward movement of the engine/tranny. I actually wasn't questioning the movement. I think its within acceptable range. I'm more concerned with the O2 hitting the steering rack housing.

Engine/Tranny mount parts for our Windstars (or at least the 95):
http://www.parts.com/oemcatalog/index.cfm?action=getJointLocator&siteid=2&chapter=&Sectionids=0,2453&groupid=51840&subgroupid=5327&componentid=0&makeid=10&model=Windstar&year=1995&graphicID=MT95210&callout=5&catalogid=2&displayCatalogid=0

Is that the factory O2-sensor or an aftermarket?

Here's why I ask. Last summer I replaced the O2-sensor on my wife's Chrysler-cirrus. I used an 02-sensor deep-socket to get it off....the type with the slit for the wires. Didn't work to put it on because the aftermarket sensor was longer, and clearances were very tight. I don't remember how much longer it was, but I do remember having to drive around until I found a crows-foot type 02-socket for the installation.

Is that the factory O2-sensor or an aftermarket?

Here's why I ask. Last summer I replaced the O2-sensor on my wife's Chrysler-cirrus. I used an 02-sensor deep-socket to get it off....the type with the slit for the wires. Didn't work to put it on because the aftermarket sensor was longer, and clearances were very tight. I don't remember how much longer it was, but I do remember having to drive around until I found a crows-foot type 02-socket for the installation.

Its aftermarket Bosch, but Bosch made the OEM O2's for Ford/Motorcraft. They are the same size and I too had to buy an O2 socket and it fit both OEM and aftermarket one.

EDIT: CORRECTION: I just went outside to compare the tops of the old OEM ones with the new Bosch ones and everything on the sensor is the same except the top metal cap of the O2 sensor which surrounds the wires. Notice if you look at the cap in your mind separately its like a little building with 3 levels/domes. The 2 top domes are wider in diameter than the OEM O2s. However, this isn't by much. This may be 1/4 to 1/2" at the very most which still puts the O2 into contact with the steering rack housing using the Magnaflow pipe or like within a couple millimeters of touching it which still leaves you having to install the O2 while the exhaust pipe is loosened.

Yet again..... lol.... I was trying to save a few bucks, but it looks like if I want to keep this pipe it would be better to install the OEM O2 (listening to Wiswind's recommendation) and COINCIDENTALLY this exact sensor is the same O2 position I suspected for O2 sensor failure due to a glowing cat some months ago now.

WOW! You guys aren't gonna believe this!
Magnaflow called/emailed me back. Their engineers liked my photos/video very much and they want me to send them my OEM Ypipe to remake theirs! COOL HUH? lol - All for an old Ford Windstar! lol - They are gonna pay for shipping etc.. and will send me the OEM pipe back along with a new remake as well! HOW ABOUT THAT HUH?

Of course what this consequently means is that my efforts here will make a difference for all future Windstar owners who'd ever again purchase this Ypipe. IE: It will fit right for them due to my pains and sorrows! lol and of course yes.... Magnaflow's too. :p

No idea on a turnaround time for this, but I don't much care. I'll just get my other car running and use it till the Windstar saga can be finished.

Do you like how my letters keep getting smaller?

Photos I sent Magnaflow:
http://www.thinkrolland.com/images/externallylinked/95WindstarMagnaFlowYpipeO2Sen-0001arrowsYpipeCompare-smaller.jpg

http://www.thinkrolland.com/images/externallylinked/95WindstarMagnaFlowYpipeO2Sen-0002arrows-smaller.jpg

http://www.thinkrolland.com/images/externallylinked/95WindstarMagnaFlowYpipeO2Sen-0002arrow-smaller.jpg

http://www.thinkrolland.com/images/externallylinked/95WindstarMagnaFlowYpipeO2Sen-0007-arrowSpace-smaller.jpg

Altho I like their straght flow design, obviously is not a direct fit. Or maybe they sold you a different year design in the hopes that all 3.8L engines would run the same under carriage design.
Maybe thats why they're asking you to send them your OEM Ypipe to remake theirs, so they can do a direct fit that can actually fit to your model.

Altho I like their straght flow design, obviously is not a direct fit. Or maybe they sold you a different year design in the hopes that all 3.8L engines would run the same under carriage design.
Maybe thats why they're asking you to send them your OEM Ypipe to remake theirs, so they can do a direct fit that can actually fit to your model.

Well it does have the right Magnaflow part # on it for 95-97 years Windstar 3.8L engine. I dunno. If I return it though I end up some weeks from now with a new Ypipe for free so thats a win win deal for me.

O2s - I put the old freshly cleaned O2's back in tonight and rebolted everything. I started it up twice and let run for just a couple minutes cause of no low fan speed. I did not receive a CEL so I'm assuming my O2's are ok since my cleaning of them and since they are self heated it seems like I would've gotten a CEL immediately though I'm probably off on that. I don't want to do a full test to operating temp though until I get my low fan speed operation back (dropping resistor).

The stock O2 "DOES" touch the steering rack housing since putting the old ones back in, but it doesn't seem to be pressing as bad as the Bosch aftermarket ones were except for one thing I'm not sure I like. The stock ones wires are closer together slightly and have less material surrounding them at the top thus the wires too and not just the O2 sensor top edge are touching the rack. This means the wires would rub back and forth every time from Park to Reverse to Drive and back again. Not sure this would ever do anything cause the rack housing is smooth and round as are the wire coverings, but I don't like it and it just shouldn't be this way.

Meanwhile I'll see if Autozone will take back the new O2's which may be a doozy cause the couple of startups I did, DID change the look of the sensor guard/tip. I'll see what a lil cleanup can do. lol - If not then I'll have to try and sell'em here or on Ebay cause I need the cash.

Just to show how the O2 was damaged here ya go:
http://www.thinkrolland.com/images/externallylinked/DamagedO2SensorFromMagnaflowYPipe-0002-smaller.jpg

http://www.thinkrolland.com/images/externallylinked/DamagedO2SensorFromMagnaflowYPipe-0003-smaller.jpg

And how about something completely unrelated! I wanted to share cause I couldn't believe how well it came out with my 3.2mp cam:
http://www.thinkrolland.com/images/externallylinked/MoonShinesBrightOverHome-0013-reducedCanvas.jpg

Anyday now Magnaflow is going to send me shipping info so I can get the Ypipe thing squared away. I'd usually move on to another brand at this point, but I'll be returning the pipe to the seller for my money back and getting a free one from Magnaflow (as their guinea pig) in return + my old pipe back as well. Hard to pass that up even though its gonna be a few weeks wait and after all I really did want Magnaflow brand cats. In any case the van will sit with tape over the exhaust manifolds till I get the new Ypipe back. Might be a good time to go buy a cover for the van cause its gonna go in the backyard till I get the new Ypipe.

The seller of the pipe said that he has sold these pipes before and never had any problems. I would venture to say that everyone who did buy this setup for sure for the 95's has an O2 sensor hitting the steering rack and for the 96 - 97's its highly likely as well. I don't list 98's because this part number was listed only for the 95 - 97's.

Magnaflow is stalling or their Finance dept is taking forever. In any case I'm about to just have their pipe modified rather than sent back. I'm less and less liking the idea of my van sitting in the back yard for 2-3 months while they pump out a new one. Even though my car is about to be back on the road and I'd have it to drive I want/NEED to put all this stuff behind me and move on.

I finally bolted up the exhaust today and I'm very unhappy to relay that the flex pipe does not line up right with the rest of the exhaust and the ypipe or the other way around. The receiving muffler side of the cat-back exhaust setup is slightly pointed down and I have no idea why. The magnaflow pipe will not allow the flanges to meet flush as the pipe extends "slanted" beyond the flange welded on it.

I have to say I've heard lots of great things about Magnaflow, but this experience has me never wanting to buy from them again. There are several parts of the Ypipe that just did not line up and were show stoppers without weld modifications. At least the weld adjustment to the pipe O2 port finally got the O2 in the right position so that it does not hit the steering rack. I will be bringing the van to the same weld shop tomorrow to finish the damn exhaust once and for all. I'm worried the flex-pipe is bent beyond its tolerance cause I can see light through the tiny holes on the other side. I'm so f'ing aggravated right now. I need this crap to be over.

Verdict: At least for the 95 Windstar 3.8L unless you want a crapload of trouble to deal with do not buy the Magnaflow Ypipe 23353. It is NOT bolt-on because its poorly made.

Magnaflow never got back with me on THEIR IDEA to remake the pipe. I contacted them and will be demanding they pay for the modifications I had to get done to make it fit right.

More info: The exhaust shop was able to cut off the excess pipe beyond the rear Ypipe flange so the flex pipe could meet flush. However their weld work has the 1st muffler touching the van underbody. The biggest problem I face now as told by the exhaust shop is the Ypipe is leaking at both manifold junctions which I guess is my fault for thinking they'd seal metal-on-metal due to the way they are designed. The leaks show themselves pretty violently by shaking the van at a certain low RPM range. Its not nearly as pleasant to drive as it was before. If this sealant crap doesn't fix it I'm done with this bs and I will be putting the OEM pipe back on.

There is a trick to getting a Ypipe like thast to seal. You want to make sure its up, and all bolts are started, and bring bolth pipes up a little at a time. If you tighted one fuly before the other, it WILL leak.


Other then that sorry about all the problems yoou have had. Almost seems it would have better to just make your own. I built my own for my Bronco, and it came out great!!!

http://i100.photobucket.com/albums/m2/Ingersoll444/ypipe7.jpg