I think that maybe to much information may cause me problems some times. I am about two days away from purchasing exhaust and I am more confused after spending countless hours reading posts and writting some of my own than I was before I started. I can not figure out what size to go with, what to leave in or take out and what if any REAL benefit I will see from any of my costs or risks. I am not trying to build a dragstar here, it can not be that technical, all I want is to effeciently and at its best tow my 5er. Some many choices and so many descisions what to do?:CRY:

 

i feel ya...i don't even own a ctd, but i'd play a heck of time trying to figure out which smarty tune to run if i had one!!!!

 

I just eliminated the muffler, my '03 did not come with a cat, and left the resonator. I Like the way it sounds as do people that hear me drive by, except late at night if Im on the go pedal. I have heard the MBRP cool duals and I dont care for them. Every has their like and dislikes. I guess all you can do is try and find video of different setups and go from there. Of course just eliminating the muffler is the cheapest way to start.

 

Either eliminate the muffler with a straight piece of pipe or install a high-flow unit in place of the factory muffler. That's all you need on an '06 to easily support lots of power.

 

The only legal way to improve your system is to install a high flow cat and high flow muffler. If your cat falls off, don't get rid of your muffler or the drone will kill you when towing. If your cat falls off, be sure to add a high flow muffler. 4" is just fine to 500 HP. Over 500 and might gain a little 5-10hp going bigger.

Problem is that your truck comes stock with 4" so it is hard to find 4" kit with what you want and what you don't want. Most guys who upgrade a 4" exhaust go to 5" cause they cost nearly the same. But that said, four is plenty, you just might have to build your own 4" kit with a high flow muffler and straight pipe for the other restrictions.

 

The factory ( 05-07) muffler and tailpipe only cost 10 hp compared to straight pipe at 800 hp. Spend your money elseware, if you are going for looks put a tip on your factory exhaust. Tim

 

On my last 04.5 and my current 06, I just changed the muffler. First truck I went with a short magnaflow and immediately went back & got the longest magnaflow. It was fine. My current I got the Donaldson 51'' muffler. Even on the dyno a couple weekends ago, the motor was much louder than the exhaust. The Donaldson was under $100.

I think it was Diesel World magazine that did a turbo back vs cat back dyno test. It was a mildly modded Duramax. HP diff's were nominal. EGT's were notably difference, if I recall correctly.

I am hoping I am accurate. Now I am curious, I am going to search for it.

 

OK, I found this. It is not the one I was looking for, though. There is a test somewhere with EGT's readings too.




http://www.dieselpowermag.com/tech/g...ust/index.html

 

Hello,

Listen to Timinva. I do not know about the 800 hp level claim but exhaust is one of the absolute last places to spend money on an 06 in your HP level.

Damon

 

thanks for all the input I think that since I got qouted 125.00 for the aero 4040xl that I will replace my cat with that on the stock system. I hope that my dealer is cool and does not throw a fit. Thanks

 

I'd count on them throwing a fit. If they don't it's nice but you should plan on them not liking it.

I still have my cat in place and I think I'll just leave it. I did straight pipe where the muffler was however.

 

This is what I wanted to hear. I'm not much for loud exhaust, but I don't wanna choke the thing down either. I cleaned out the cat and left the empty can there, will that hurt me any?

 

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:

 

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.