pluguglyinhere

Ok maybe some of you can add some insight for me. I am not trying to build major horsepower. I am looking to effeciently tow my 8500lb 5er. I am looking for that right mix of towing performance and effeciency. I took of my muffler to see if I saw a difference and logged about 10000 towing and realy saw nothing. It is to loud, so a change is in need for sure. Any real world experience with exhaust sizes, brands, cat back, turbo back, what to do. thanks

supr

You already have a 4" exhaust, I believe.
I would put the sock muffer back, unless you like noise.
Edge EZ is recommded for slight HP & mileage.
A K&N drop in or BHAF might help too.
Keeping your speed towing 55-60 will help mileage, as ewll as airing up all tires to max or near there.
I tink I read that some differrent injectors may also help.
I would say the Edge & K&N will give he most for he least $.
My $.02

DaveB.inVa

supr is correct, you already have a 4" exhaust. If you dont want the restriction of the stock muffler then try a Donaldson or Nelson truck muffler. You can get them in 40" or 51" versions and they're pretty cheap too. There are tons of threads out there on this very subject so you can search and read all night.

For a filter I don't really like oiled media. I've seen the oil be sucked out and coat the turbo blades before!

I have an Amsoil nanofiber filter and it filters great and has about 1.5x the flow of the stock filter. Its drop in and reusable.

For decent hp check out the Smarty Jr!

TNContractor

My 5'er weighs about the same as yours and my skid steer/ trailer combo weighs more. I have an AFE intake and EZ and I am very pleased. Last trip was from east TN to just above Roanoke Va. In a VERY strong crosswind and got 14.4 mpg going up and 15.4 coming back (hand calc.) and w/o the massive wind. Avg. speed 65 mph. (Va.'s finest REALLY don't like you to speed!!!!) I do wish I had waited a few months for the Smarty Jr.

DaveB.inVa

Yes... don't speed here!

TNContractor, I'm not too far from you. I'm just across the TN/VA line from Kingsport. I have some relatives that live in Blaine so I go through Bean Station ever so often.

pluguglyinhere

Well with 48 hours left till I do my exhaust it seems that it makes sense to add a 4040xl to my stock 4inch. I believe that a full 5" turbo back will lower my egts more than the 4" no doubt but is not needed for my horsepower level other than that. I think that the 5" will not benefit compared to the cost.

The muffler is already gone so the only two descisions now are where to put the 4040xl?

Should it be close to the turbo or where the stock muffler was?

Then the whole what to do with the other part in the 06 exhaust that I can not mention in some forums versus the dealer and federal regulations?

I am getting closer:hyper:

Hunter11

I currently have a MBRP replacement muffler on my truck and would like to replace it. We are on the road and the wife and I have decided it is just to loud pulling the 5th wheel. I would like to stay with a higher flowing muffler but do not want the noise. The Donalson and Nelson sound like the way to go so where is the best place to get one online? I assume the 50" would be the best one to keep the noise down.

Rednax

Owner previous to me installed an Aeroturbine. Nice punk kid sound when around town, a total PITA on the highway. Added a RokkTech muffler and moved the Aeroturbine forward to act as a resonator. Hardly know it's a diesel with the windows up. Mileage is above 22 mpg solo, and 15-16 on Interstate, towing.

pluguglyinhere

Well it is done, Monday night I installed a 4040XL into the system and the cat test pipe. That reminds me I need to put that back in now that i am done testing. The cost was 165.00 aero, hangers, clamps and pipe.

I say in advance that I have only logged about 60 miles since. I will put about 2000 miles on this new system towing my 5er starting tommorrow and will report.

The sound seems great, It may have a little fart can sound when I first romp on it, but idle and cruising sound great. It is much quieter than before with no muffler just cat. I can hear my turbo again and order fast food.

The EGTs seem to be at least 100 degrees cooler all around no more than 200. The trip towing will be the test for this for sure.

I still believe that the 5" would lower egts more than 4" no doubt. I also think that between cost and my stock truck this was the best route. It would not be worth the money to lower another 50-100 degrees. If I was pushing big numbers and that meant the difference between a run at 1400 degrees and 1300 degrees then sure.

The place I bought the aero from would sell me a 5" kit with an aero cheaper than anywhere else I could find here or otherwise. They also let me hear two trucks (Dodges 3rd gens), one with 5" straight aero 5050xl and one 4" straight 4040xl. My test revealed that 5" is louder therefore not what I wanted.

Finally I am sure that I could get 1 or 2 more mpgs from a chip/programmer/module and liked the smarty jr. I decided against it for now because of all the varying information. The savings from it would take a long time to replace the transmission. I got feedback that 30hp driven conservative would do damage eventually and the other end was feedback that running hard on much more had resulted in no problems for years. I dunno, again may just not be worth it for me.

Thanks for all the input, I am happy for now and will report out upon returning from my trip.

dogger

I have the same setup as you for the exhaust and it is still a little loud for me. I am thinking that since I have a 4" exhaust now I will go with an 05 stock muffler as the 03 was originally setup with a 3 1/2" exhaust; with the 4" I have a 1/3 more pipe area. The biggest restriction in the exhaust system is still the turbo.

L8r,...........dogger

pluguglyinhere

Well the Aero 4040Xl is great my egts are down at least 200 degrees. I did not see a real mpg difference for sure. I was getting about 10-12 with my treavel trailer and I got 11-12 with the new 5er. The exhaust and 5er are new so not sure wich made the difference for sure. I can tell you though that wether towing or not my gauges are down from the exhuast. I am glad I went the way I did this thing is quiet cruising and jumps out when you hop on it.

Is still wish that I could get about 14 mpg towing my trailer but that is probable a pipe dream. FYI I towed pretty much 65 the whole time trying to keep the rpms around 1800-2000. I tested a couple of tanks at other speeds but most was at 65/1800-2000.

Rednax

I'll be interested to know how much better you find the above to be than the Rokktech/Aeroturbine combination. Mine "seems" to be as quiet as most stock trucks (RV parks are full of 'em), and I hope you'll post your results. I don't have EGT or other gauges so I can't comment on that aspect, but I'd sure be glad of some numbers!

Thanks.