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4x4 Exhaust Parts Buyers Guide

Posted in How To: Engine on October 1, 2005
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Next to tires and wheels, tweaking the exhaust is one of the easiest, quickest, and longest-lasting improvements you can make to your truck, and that includes for performance, sound, and looks. Want a new growl and increased fuel mileage? Want improved flow, reduced exhaust temperatures, and more horsepower and torque? Want dual pipes or a sporty tip? Have a rusty system? A trail-mangled pretzel? Smog nazis on your back? There's something for everyone, with upgrades aplenty for whatever you're craving and no matter what your wallet allows, from header to tip. Prices listed here are those that were available as of press time.

The Part: Monster Split-Dual exhaust system for Power Stroke, Cummins, and Duramax diesels.
What It Costs: Starts at $629 (after-cat Split-Dual system).
Exhausting Detail: 100-percent stainless-steel exhaust that accommodates a spare tire. It's available as turbo-back or after-cat, and the single-inlet Monster muffler "Ys" to two 3 1/2-inch mandrel-bent tailpipes. The muffler has an exclusive expansion chamber for dissipating mid-range drone.
Who's Got It: Gale Banks Engineering, 800/277-1991,

The Part: Cat-back system for the Jeep Unlimited.
What It Costs: $439.99.
Exhausting Detail: "Straight-through" and "multicore technology" are the buzz phrases for this unique system, which has T-304 stainless steel, mandrel bends, and computer-controlled CNC manufacturing for a precise fit.
Who's Got It: Borla Performance Industries, 877/452-6752,

The Part: Exhaust line for the Power Stroke, Cummins, and Duramax diesels.
What It Costs: $898.50.
Exhausting Detail: Systems are manufactured from 4-inch T-304 stainless-steel tubing that is mandrel-bent and polished. There's a double-wall 5-inch tip, and the entire exhaust bolts up using the factory hangers and flanges.
Who's Got It: Volant Cold Air Intakes, 909/476-7225,

The Part: Generation II copper exhaust insulating wrap.
What It Costs: Starts at $32 a roll.
Exhausting Detail: It's designed to improve heat performance (and reduce underhood temps) by using Thermal-Conduction-Technology coating (T-C-T). It's sold in 1- and 2-inch-wide, 50-foot rolls.
Who's Got It: Thermo-Tec, 800/274-8437,

The Part: DMH Performance Dump Valve
What It Costs: $199 to $360, depending on size.
Exhausting Detail: DMH Electric Cutouts are welded into your stock or modified exhaust system. They can be placed anywhere after the headers. At the touch of a button, the valve enables you to bypass your muffler, increasing horsepower and giving your 4x4 an extremely throaty rumble.
Who's Got It: DMH Performance, 513/753-3866,

The Part: Chrome exhaust tips for '03-'06 GM fullsize SUVs.
What It Costs: MSRP is $60.
Exhausting Detail: The steel tips are meant to attach to the tailpipe section of the exhaust, and it's said they won't rust or corrode. Versions for the fullsize pickups are coming soon.
Who's Got It: GM Performance Parts, 800/GM-USE-US,

The Part: Rapid Flow exhaust system for Power Stroke, Cummins, and Duramax diesels.
What It Costs: Starts at $550 for the 4-inch aluminized system.
Exhausting Detail: Available in 16-gauge T-304 stainless steel or T-409 stainless steel, Rapid Flow has minimal-degree angles of mandrel bends. There are 4-, 5-, and 6-inch systems, as well as dual exhaust.
Who's Got It: Bully Dog Technologies, 208/397-3200,

The Part: SuperStainless catalytic converters for most pickups and SUVs.
What It Costs: Ranges from $209.44 to $259.01.
Exhausting Detail: High-flow cats are direct-fit, bolt-in units for most vehicles and have the necessary flanges and O2 sensors (if needed) as the OE converter's. If your vehicle is registered in California, aftermarket cats are not legal for use on OBD II rides.
Who's Got It: Random Technology, 770/554-4242,

The Part: '04-'05 Dodge Durango Hemi exhaust system.
What It Costs: $813.19.
Exhausting Detail: Uses patented Reflective Sound Cancellation for big sound at acceleration but quiet note at cruising speeds. Has a straight-through, non-restrictive design and is constructed of 3-inch T-304 stainless steel.
Who's Got It: CORSA Performance, 800/486-0999,

The Part: Split-rear exhaust for '98-'03 Ford F-150 and '04 F-150 Heritage (compatible with the 4.6L and 5.4L engines).
What It Costs: MSRP is $750.
Exhausting Detail: This system is made of T-304 stainless steel and has unique tips. There are additional lengths to fit all wheelbases included in the kit.
Who's Got It: Ford Racing Performance Parts, 586/468-1356,

The Part: Complete exhaust systems for Power Stroke, Cummins, and Duramax diesels.
What It Costs: $395 to $1,295.
Exhausting Detail: 4-inch mandrel-bent Grade T-409 stainless tubing from the turbo back, with a polished Grade T-304 stainless muffler. There's more than 1-inch clearance down the back of the firewall, and the 5-inch, slash-cut, radius-rolled 24-inch-long T-304 stainless tips can be positioned to any custom length.
Who's Got It: ATS Diesel Performance, 800/949-6002,

The Part: Therminator Series high-performance exhaust system for the Power Stroke, Cummins, and Duramax diesels.
What It Costs: Starts at $550 for turbo-backs; downpipes and after-cats available for less.
Exhausting Detail: Constructed of aluminized steel, it uses mandrel bends and free-flowing mufflers. The Duramax is downpipe-back style, made of 4-inch tubing, while the Cummins is turbo-to-tailpipe and in 4- and 5-inch sizes; the Power Stroke uses 3 1/2-inch downpipes with 4-inch after-cats.
Who's Got It: Diesel Dynamics, 800/628-8111 or 702/897-6263,

The Part: 50-state-legal headers for '00-'04 Toyota Tundra and '02-'03 Sequoia.
What It Costs: Ceramic, $500; high-temp paint, $325.
Exhausting Detail: Made from 16-gauge tubing with 1 1/2-inch mandrel-bent primaries, the headers have 3/8-inch-thick machined flanges and bolt to the stock exhaust headpipes. They come finished with either ceramic coating or high-heat-resistant black paint.
Who's Got It: Flowtech, 270/781-9741,

The Part: Performance Package for Power Stroke, Cummins, and Duramax diesels.
What It Costs: Starts at $845 for Dodge system.
Exhausting Detail: This air/fuel management stainless and aluminized exhaust kit features an XMonitor display with built-in memory and warning system that can be mounted on the dash or A-pillar. The XIntake system reduces exhaust temps and makes the engine compartment more purty.
Who's Got It: BD Diesel Performance, 800/887-5030,

The Part: Shorty headers for Jeeps with the 4.0L engine.
What It Costs: $448.95 for the extra-heat-resistant Ti-TECH coating; $506.95 for the ceramic coating.
Exhausting Detail: The headers have a tri-Y design and bolt right to the stock exhaust (they hook directly to the factory crossover pipe sans welding or cutting). There are 1-inch-diameter T-409 stainless steel primary tubes.
Who's Got It: Edelbrock Corp., 800/FUN-TEAM or 800/416-8628 (tech),

The Part: American Thunder Dual 2 1/2-inch exhaust system for the '04-'05 Nissan Titan.
What It Costs: $660.
Exhausting Detail: The after-cat system has a two-into-one scavenger Y-pipe assembly, side or rear tailpipe exit, a 3-inch inlet pipe, a 70 Series muffler, and dual mandrel-bent 2 1/2-inch tailpipes. The 3-inch, rolled-edge tips are included.
Who's Got It: Flowmaster, 800/544-4761,

The Part: Log manifold header system for '03-'05 HEMI Dodge Durangos and 1500 Rams.
What It Costs: MSRP is $880.59.
Exhausting Detail: The OE replacement is 50-state legal and said to be ideal for towing. It's constructed out of T-304 stainless steel and is ceramic thermal-coated inside and out.
Who's Got It: Gibson Performance Exhaust, 800/528-3044,

The Part: Super Turbo exhaust system for the '05 Jeep Wrangler and Wrangler Rubicon.
What It Costs: MSRP is $200.
Exhausting Detail: The after-cat system has a Super Turbo muffler with patented flow technology, plus a polished stainless steel tip. It has been designed to follow OE exhaust routing, and includes all hardware.
Who's Got It: DynoMax, 734/384-7806,

The Part: Headers for '99-'03 Chevy trucks or SUVs.
What It Costs: Starts at $230.
Exhausting Detail: The headers-or Hedders-are 50-state legal, have 1 5/8-inch mandrel-bent primary tubes, 1 3/8-inch head flange, and OE-style collector flanges for simple installation. They're available with a ceramic-metallic coating.
Who's Got It: Hedman Hedders, 562/921-0404,

The Part: High-temp metallic-ceramic coating.
What It Costs: Depends. Typically runs $50 to $200 and will take 5 to 7 days.
Exhausting Detail: The exhaust-component coating serves as a thermal barrier, keeping the exhaust heat in the pipe, not radiating outward, which can reduce the header temp by half. It also can prevent corrosion.
Who's Got It: JET-HOT, 800/432-3379,

The Part:Vortex Classic high-performance muffler.
What It Costs: Starts at $65.
Exhausting Detail: The high-flow reversible design has an internal flow rate similar to a 4-inch straight-through pipe. It's welded from aluminized 14-gauge steel and has a black high-temp powdercoating. Sizes range from 2 1/4- to 3-inch inlet and outlet.
Who's Got It: Supreme Performance, 800/445-7616,

The Part: QPM-639 muffler for diesel pickups.
What It Costs: MSRP is $269.39.
Exhausting Detail: The QP is for a "quiet performance" technology, the secret to sound, performance, and mpg improvements for this system.
Who's Got It: Grand Rock, 800/321-3674 or 440/639-2000,

The Part: Exhaust line for gas-powered Ford, GM, and Dodge trucks and SUVs.
What It Costs: Sport System starts at $439.10.N/A
Exhausting Detail: The systems are made of T-304 stainless steel or aluminized, and include the tip. You can choose between Super Single and Cool Dual configurations.
Who's Got It: MBRP Performance Exhaust, 888/636-7223,

The Part: 4-inch exhaust system for '99-'04 Power Stroke and '01-'05 Duramax Diesels.
What It Costs: Starts at $510 (Duramax after-cat); $695 for Power Stroke.
Exhausting Detail: The after-cat bolts directly to the backside of the catalytic converter, while the downpipe-back attaches to the V-band clamp at the end of the stock downpipe. The pipes are 4-inch stainless steel and have a 5-inch tip.
Who's Got It: TTS, 310/669-8101,

The Part: After-cat exhaust system for '91-'04 Jeep Wrangler YJs, and TJs.
What It Costs: Starts at $497.92.
Exhausting Detail: Consists of a polished stainless steel straight-through muffler, 2 1/2-inch mandrel-bent tubing, and a 2 1/2-inch turndown stainless-steel polished tip.
Who's Got It: MagnaFlow, 949/858-5900,

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