Exhaust
This part is highly subjective, as the “perfect” exhaust note depends on one’s taste. I will summarize this section.
Cat-Back Exhaust
The stock catback, though extremely quiet, is actually not that restrictive. Upgrading to an aftermarket exhaust will not net a worthwhile gain if you are just looking at it for power, but sound and replacing the rattle-prone flex-pipes (which will rattle in the future no matter what) are the pluses.
Stock Cat back with Aftermarket Tips
If you like the quiet exhaust but want something better looking than the tiny 2” quad-tips that come stock, it is quite simple to make it look better. 3” quad-tips with a 2” inlet slips right on with no fabrication. It is as simple as cutting off the stock tips, and welding in or screwing in the new exhaust tips. I do not recommend screw-in type tips, as they have a good probability of falling off. 4” exhaust tips will fit with some fabrication, but you will need a 2.5” inlet so that you can properly space the tips. They will fit in the diffuser perfectly but are not as easy as just slipping them on.
Muffler Delete Axle-Back
A very cheap option is to do a muffler delete. It sounds decent, but it will drone like crazy on the highway.
Resonator Delete
A resonator delete usually does wonders, as shown in the Mustang GT for example. Unfortunately the res delete on these Explorer’s will give it a very tinny sound as well as some drone.
Thermal R&D 2.5” Exhaust
This is the best exhaust for people who want some more sound when they step on it, but quite on everything else, the Thermal 2.5” Exhaust is the best choice for them.
Thermal R&D 3” Exhaust
One of the top all-around exhaust is the Thermal 3” exhaust. Zero drone, mild sound when normal driving, and awesome sounding on acceleration. This is a great exhaust for people who want to hear EcoBoost sing the best song it can sing.
AWE Exhaust
Another exhaust that is great, is the AWE Exhaust. Same pros as the Thermal, zero drone, mild sound when normal driving, and awesome sounding on acceleration. The exhaust tips are awesome too, 4″ exhaust tips fill in the rear valance awesomely. It does have a deeper exhaust note I noticed over the Thermal.
Downpipes
Downpipes are a great upgrade and help reduce restriction from the turbos. They also replace the crack-prone downpipes from the factory. Downpipes have been tested to show gains of up to 15 HP on pump gas. Fen fabrication, CVF, and SPD are all great with no difference between them, just price.
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Explorer ST Enthusiasts 