Some exhaust upgrade info

joezek · Jul 25, 2010

I'm buying a 2003 expedition, 5.4L I think, I don't think I'm getting the one with the 4.6L. My plans are to pretty quickly upgrade the exhaust system. My goal is not for power, but for fuel economy. I've heard the non mandrel exhaust is pretty restrictive on these trucks.

On a low budget, does anyone have suggestions to headers, and exhaust? What is the pipe diameter? Are there cat delete setups available?

I would like to install headers, cat delete, and true dual exhaust with quiet mufflers.

My short term goal is to get as close to 20 mpg as possible on the highway to justify switching from my explorer to the expedition.

I have two high flow catalytic converters, 2 1/4" pipes, stainless. If they won't fit then I'll sell em.

tallsville · Jul 25, 2010

on my 03 4x4 xlt. i have a k&n intake and spintech cat back. on highway if i keep it around 1800 rpm around 68mph. i get around 18mpg. city driving around 14mpg. as far as true duals unless you turn down or go out in front of rear tire the independent rear suspension prevents a true dual setup exiting rear. no room for 2 pipes to exit.

walnuts4x4 · Jul 25, 2010

look into a programmer like an EDGE CS... I'm averaging 11.9-12.1 MPG on 37s with the 3.73 gears still...

joezek · Jul 26, 2010

I see that headers come with 2.5" outlet/collectors. I guess I'll have to get 2.5" converters if I keep em. Anyone want my 2.25" ones? Also, the explorer uses a dual exhaust all the way back to the muffler, then single outlet after the muffler.... possibly it will help on the expedition if I do this?

tallsville · Jul 28, 2010

the dual in single out helped my expy. i have a pic of exhaust setup in show and tell, if you want to see.

Spooky · Jul 28, 2010

tallsville said:
the dual in single out helped my expy. i have a pic of exhaust setup in show and tell, if you want to see.

Yes, pics please.

tallsville · Jul 28, 2010

here are some pics of my two into one exhaust. if i can pics of my old 97 expy with dual in dual out exhaust i will post those.

joezek · Jul 30, 2010

That exhaust is really nice, I'm going to show those pics to whoever does my exhaust, so they do it right. Is there room to have a dual outlet muffler, with two pipes side by side right over the rear axle? That must have made a pretty big power gain, the stock y pipe is horribly restrictive looking.

tallsville · Jul 30, 2010

no room for dual pipes over independent rear suspension(irs). thats y i did a dual in single out. pics 3 and 4 show the single pipe going over rear axle. sorry light in 3rd pic makes i kinda hard to see

joezek · Jul 30, 2010

I'm guessing you have dual 2 1/2" inlets and single 3" outlet?

What were the gains with mileage, and power too.

kenzo14 · Sep 17, 2010

Nice set of exhaust you got there tallsville.. I might change my exhaust system to that kinds.. I smell power gain.

tallsville · Sep 17, 2010

@joezek. sorry forgot about this post. yes its 2.5 in 3 out. its been 5 yrs since i put the exhaust in so if i remember correctly it was a couple mpg more. i get 18mpg on hwy about 14 city. but i also put the k&n fipk on a month earlier. as far as power goes you can feel the difference. you can check my exhaust post in this section. there is a youtube video from inside. so you can see and hear what the exhaust is like.

WHOISMOOTOO · Sep 17, 2010

you can always run a y pipe right after the last bend

cbiii · Sep 17, 2010

WHOISMOOTOO said:
you can always run a y pipe right after the last bend

dont take this the wrong way...but did ray charles do those welds??
and why would you want to do something like that? just for the look? you could have bought a y from oriellys or autozone or somewhere just as easily.

WHOISMOOTOO · Sep 17, 2010

i feel you cbiii i was pissed at first, it was a mom and pop shop and the tips i got werent an exact 45 degree cut (i realized that after the job was dont)so it was necessary for it to be crooked (if that makes sense)

i got this done when i put my flowmaster on i wanted chrome tips side by side but i didnt want to be able to see the welds from the back of the truck so i got the long tips. i left and ate lunch and this is what i came back to, i got it all for free in the end. it looks horrible from the bottom but from the side you can barely tell because there actually even from the side, look at the sig pic so i just left it as is

tallsville · Sep 17, 2010

got an oil change today. they had it on a lift so i took a pic of the whole exhaust.

nate66 · Sep 18, 2010

I have a 1999 Expedition XLT. I see there are o2 sensors on the second set of cats. anyway to get around these? cat delete?

GAINMOB · Sep 18, 2010

you'd have to go to a muffler shop unless youre a muffler man...since ur asking for help...the later doesnt apply....ne way go to a muffler shop...04-06 EBs cant do true duals because of the way they redesigned everything underneath...i've seen 03's with true duals but 04-06 they dont have the room/clearance to run split or side-by-side duals...they tried to use the smallest piping they had and couldnt do it....the left side doesnt have the clearance like the right...cant fit 2 pipes on the right...main reason why WHOISMOOTOO did what he did...i'm going to do it too...

nate66 · Sep 19, 2010

Alright sounds good. Thank you.

dub_edition03 · Sep 29, 2010

bhsoulja said:
you'd have to go to a muffler shop unless youre a muffler man...since ur asking for help...the later doesnt apply....ne way go to a muffler shop...04-06 EBs cant do true duals because of the way they redesigned everything underneath...i've seen 03's with true duals but 04-06 they dont have the room/clearance to run split or side-by-side duals...they tried to use the smallest piping they had and couldnt do it....the left side doesnt have the clearance like the right...cant fit 2 pipes on the right...main reason why WHOISMOOTOO did what he did...i'm going to do it too...

i have a single inlet dual outlet exhaust.. i had to take out the hitch and spare because i wanted it to come out a certian way.. but when the dude ran the 2 pipes he had to do alot of bending and cutting. but he was able to run both pipes out to the back.. if you pay attention on the passanger side i want to say its on the side of the control arm the dude ran both exhaust pipes... the barely fit.. i paid 450.00 for everything flowmaster labor, tips...ect im sure there is a way to fit a dual exhaust system on your expy.. the only reason i didnt run duals is because i hear that on the 4.6L you lose hp.. that it sounds like crap also.. i didnt want to take that risk..

Some exhaust upgrade info

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