I have been reading up about just changing the muffler. I DO plan to do a whole exhaust upgrade( stacks) at some point, but not htis year. so i figured , maybe i`ll put a Donaldson muffler in place of the stock on e for now.

My question is, with the muffler(part # mo85171) being a straight through design, and the stock one having offset connections, how do you make it fit?

I realise that you have to put addapters in there to go from 3.5" to 4".

But about a foot before the stock muffler, the exhaust pipe takes a small bend downwards, and doesnt line up with the tailpipe. should i order a piece of 4" pipe, and cut the existing off before it offsets?

Just wondering how some people have done it.


THX

 

I went from the back of the down pipe to the tail pipe just behind the muffler with a piece of 4" straight pipe and it lined up just fine. Sounds cool too!!!!!!!

 

has anyone used the Banks downpipe so that you have full 4" turbo back without the 3.5" cast elbow?

 

I am in the process...Banks DP with Donaldson Muffler and Stock Tailpipe. Nitro is also doing the same with a Flow Pro Muffler. One of us will post as soon as it is finished...

 

are you sure the cast elbow is 3 1/2"?, when i look at mine, the PIPE drops from 4" to 3 1/2" right AFTER the cast elbow.

 

you might have one of the lucky early 03s. Rod has pointed out that some of these escaped the factory with a 4" elbow. I just looked at mine, and the cast elbow definately necks down to a smaller diameter than the turbo outlet, and the downpipe never changes diameter.

which brings me to an interesting question: how do you fit a 3 1/2" factory (jacobs) exhaust brake onto a 4" outlet? Were all the escapees automatics (no factory approved solution)?

And for guys that are using the Banks 409 stainless downpipe (replacing the cast elbow) -- how's 1000 degrees treeting the 409? (in other words, is that elbow cast for a reason.)

 

if that is true, i wonder how that will effect me when i upgrade ehaust.
If the majority of the systems out there are designed to come off a 3.5 inch cast elbow, and i have a 4 inch elbow.......I will have to keep that in mind.

 

another thought here. the 600/325 elbow is full 4". Chrysler won't part it out because its integrated in with the turbocharger as one part number. when will someone figure out how to obtain this elbow from Cummins and sell them as an upgrade to the 03-04 turbos?

I'm thinking cast is better than 409 stainless and would rather have a 4" cast elbow!

 

dodgedude: the 04.5 is also full 4" (stock). I bet you could use that downpipe but yea you'll have to watch out because the bolt on systems won't bolt on. nice problem to have though. I bet most any exhaust shop would bend a 4" pipe for you. Is your truck a 6-speed? if so, you could go to the dealer and ask how on earth they would install a factory jacobs brake! or if your's is an auto, ask them how they would replace your downpipe if necessary

That aside think about this: Since the 04.5s are full 4" elbows, that means the exhaust brake folks will have to make 4" brakes that bolt up to the turbocharger. what a bonus! now the 03-04 guys that upgrade their turbos can now AVOID THE INLINE BRAKES! well, am I wrong about this? why not bolt up a 4" 04.5 turbo-mounted brake to a 4" after market turbo on an 03?

patience may pay off. I think I'll wait to see if the above scenario happens.

 

Nice job Doug, no i have an auto. i dont have much need for an Ebrake.....as of now. I tow a 6,000lb TT , and even if i upgrade, it wont be by much. I tow rarely, few times a year. i did tow through the PA mountains last summer, no problem.

As far as an exhaust shop bending some 4 inch pipe for me.... no luck. In my neck of the woods, diesel performance shops dont exist, that i can tell. I called my local muffler places( Midas, and such) they only stock 3 inch pipe, and could order 4 inch, but they dont have the machine to bend it. I have been calling them just to put a pipe in place of the muffler for now.

At this point, i`m better off bying my own pipe, and clamps from "air flow systems" and doing it myself.I do plan to replace everythung at somepoint, maybe next year. By then i`m sure i`ll have more options.

Thx again Doug