3.5 duratec true dual exhaust upgrade

[cfd911]

Hey group i ‘m thinking about installing a true dual exhaust for my 3.5 duratec from a 3.7 piu , what are your thoughts?

 

[Fix4Dirt]

Hey group i ‘m thinking about installing a true dual exhaust for my 3.5 duratec from a 3.7 piu , what are your thoughts?

im always onboard for any mods! any sound clips from others? is it bolt on?

 

[Digitalgp]

The exhaust from a 3.7 PIU is a direct swap to your n/a 3.5 as long as you get everything behind the manifolds. I don't know if there is any gain to be had switching to a true dual stock setup. Me personally I would cut out a section and put in a X-pipe or H-pipe for better flow.

The driver side muffler on my '15 xlt has a nice crack in it right at the seam, the passenger side isn't leaking yet, but doesn't look too far behind. The rest of my exhaust is solid so I've been trying to look in to different options

 

[AdamWest436]

Keep us updated, I toyed around with the idea since that squashed y piece pisses me off every time I remember it's there. It's way better than the GM u pipe in the 90's GM's for the rear o2 sensors.

 

[Digitalgp]

Yeah I get the same feeling with the front pipe of this explorer, but definitely far better flowing than the awful u-pipe on the w-body GM's. Getting rid of that pipe was one of the first things I did when I bought my Grand Prix.

 

[AdamWest436]

Hey group i ‘m thinking about installing a true dual exhaust for my 3.5 duratec from a 3.7 piu , what are your thoughts?

Any updates on this? Was debating late future to X pipe those flanges at the end and go from there. Also would this front piece get us in the vacinity of going aftermarket Sport cat backs?

Original 2013-2019 Ford Police Interceptor Utility Front Pipe DB5Z-5G203-A | Levittown Ford Parts

2013-2019 Ford Police Interceptor Utility part # DB5Z-5G203-A - Front Pipe

parts.levittownfordparts.com

 

[Digitalgp]

Not to hi-jack this thread, but I am going through with this exhaust swap within the coming weeks as I obtained an entire 3.7 PIU exhaust system. For comparison the front pipe is a little shorter, but the catback itself is a little longer. From what I see looks like everything will line up. I do have some issues I foresee with the swap

1) The front exhaust hanger. The n/a 3.5 only has 1 hanger on the front passenger side where as the 3.7 exhaust has one on the driver side as well. Depending on how it works with just the one side being held up I may have to fabricate a bracket with a rubber hanger for the driver side.

2) The catback itself is in pretty good shape and the mufflers are still solid, however on the front pipe the one flexpipe is splitting. I am trying to decide if its more cost effective to have a replacement flex section welded in or to just purchase an entire new front pipe assembly. I would have both flex sections replaced just for peace of mind.

3) Cutting off the turn downs and putting on chrome stock style tips. Just personal preference

 

[AdamWest436]

Not to hi-jack this thread, but I am going through with this exhaust swap within the coming weeks as I obtained an entire 3.7 PIU exhaust system. For comparison the front pipe is a little shorter, but the catback itself is a little longer. From what I see looks like everything will line up. I do have some issues I foresee with the swap

1) The front exhaust hanger. The n/a 3.5 only has 1 hanger on the front passenger side where as the 3.7 exhaust has one on the driver side as well. Depending on how it works with just the one side being held up I may have to fabricate a bracket with a rubber hanger for the driver side.

2) The catback itself is in pretty good shape and the mufflers are still solid, however on the front pipe the one flexpipe is splitting. I am trying to decide if its more cost effective to have a replacement flex section welded in or to just purchase an entire new front pipe assembly. I would have both flex sections replaced just for peace of mind.

3) Cutting off the turn downs and putting on chrome stock style tips. Just personal preference

1&2) take caution of the dual flex pipe with just 1 bracket, My oem single flex pipe is how I ended up down the exhaust rabbit hole. I'm on my 3rd flex after experimenting with a few After Market units. Being up north the used dual pipes are questionable with Cleveland winters. My oem flex went at 40K miles for reference and the Y pipe are like $400 before ship. The 3.7 new was $300 before $30 shipping when I looked but I just had the shop put a new flex on the old one. I plan on revisiting the dual setup once I figure out my mufflers setup and how quiet I want to be again.

3) I tracked down a dual cutout insert as the bumper that didn't come with duals puts the non turndown pipes behind the bumper. Trying to mod the exhaust to angle down under the bumper could cause the flex pipe(s) to go prematurely. I got lucky after a super long fleabay search for a decent used non 360 spin out and smacked into a barrier looking piece that was going to fit a 19 bumper. I also had an issue with tips being too short the fumes got sucked in the rear HVAC more. Currently they stick out past the bumper enough to not get sucked back in but still close enough to steam up the bumper and back glass at cold start idle. Going from turn downs to staight back quads I now have the entire back glass fog up if I floor it.

This was all mufflers deleted and a Delta 50 in place of mid resonator. My end goal is try and get X pipe to see if it transitions the sound better.



This was Delta with 1 Vibrant Ultra Quiet mid pipe.



Current setup is 2 Vibrant and 50 mid pipe. That exterior video never uploaded, it's got the same or more rocky disturbance as the last one. Not many parking lots I can set a tripod up and hope no one tries to steal my phone. I did an inside windows up and down video until find a suitable place to film.

 

[Digitalgp]

1&2) take caution of the dual flex pipe with just 1 bracket, My oem single flex pipe is how I ended up down the exhaust rabbit hole. I'm on my 3rd flex after experimenting with a few After Market units. Being up north the used dual pipes are questionable with Cleveland winters. My oem flex went at 40K miles for reference and the Y pipe are like $400 before ship. The 3.7 new was $300 before $30 shipping when I looked but I just had the shop put a new flex on the old one. I plan on revisiting the dual setup once I figure out my mufflers setup and how quiet I want to be again.

3) I tracked down a dual cutout insert as the bumper that didn't come with duals puts the non turndown pipes behind the bumper. Trying to mod the exhaust to angle down under the bumper could cause the flex pipe(s) to go prematurely. I got lucky after a super long fleabay search for a decent used non 360 spin out and smacked into a barrier looking piece that was going to fit a 19 bumper. I also had an issue with tips being too short the fumes got sucked in the rear HVAC more. Currently they stick out past the bumper enough to not get sucked back in but still close enough to steam up the bumper and back glass at cold start idle. Going from turn downs to staight back quads I now have the entire back glass fog up if I floor it.

This was all mufflers deleted and a Delta 50 in place of mid resonator. My end goal is try and get X pipe to see if it transitions the sound better.



This was Delta with 1 Vibrant Ultra Quiet mid pipe.



Current setup is 2 Vibrant and 50 mid pipe. That exterior video never uploaded, it's got the same or more rocky disturbance as the last one. Not many parking lots I can set a tripod up and hope no one tries to steal my phone. I did an inside windows up and down video until find a suitable place to film.

I plan on rigging something up for the extra hanger just to give it some extra support. Your setup sounds pretty good especially after the addition of the vibrant mufflers on top of the flowmaster. Sounds pretty close to stock inside, but a little tone outside

 

[AdamWest436]

I plan on rigging something up for the extra hanger just to give it some extra support. Your setup sounds pretty good especially after the addition of the vibrant mufflers on top of the flowmaster. Sounds pretty close to stock inside, but a little tone outside

OK took the dive, the 3.7 dual fits, rest after that is fab work. What ended up happening is the sound changed from the y to the dual intermediate setup. I'm gonna give it a few months and revisit with an X pipe and Flowmasters. I swapped to "Magnaflow like" mufflers and they killed the drone but the low bass is also gone. When I get a chance and the weather gets better I'll try and get pics and video. My issues was FM droned when the car was in FWD to AWD loop & 1500 to 2800 rpms.

 

[K.H. Briger]

OK took the dive, the 3.7 dual fits, rest after that is fab work. What ended up happening is the sound changed from the y to the dual intermediate setup. I'm gonna give it a few months and revisit with an X pipe and Flowmasters. I swapped to "Magnaflow like" mufflers and they killed the drone but the low bass is also gone. When I get a chance and the weather gets better I'll try and get pics and video. My issues was FM droned when the car was in fwd to awd loop & 1500 to 2800 rpms.

I would appreciate an update as to how it is working out for you. I am considering the 3.7 true dual update for my 18 3.5 N/A XLT. Thanks in advance.

 

[AdamWest436]

I would appreciate an update as to how it is working out for you. I am considering the 3.7 true dual update for my 18 3.5 N/A XLT. Thanks in advance.

I finally finished my dual setup with the help of a local shop (Mufflers for Less) over the years and about 8 different mufflers configuration and 3 flex pipes (that lead me to touching the exhaust) ending in the current setup below.

Genuine Ford Front Pipe DB5Z-5G203-A
Custom Bent X Pipe from the shop
MagnaFlow X-PIPE Performance Muffler | 2.25 in. Inlet/Outlet Model 11385
More custom bent tubing from the Maganaflow back
Reused 2 faux Magnaflow straight though Mufflers
NETAMI 2.25' Inlet to 3" Quad Staggered Outlet Stainless Steel Exhaust Tip Double Wall Black Powder Coated Model NT-1624-2BK

I don't have any new videos besides an idle cold start worth posting yet and I failed to get a sound clip of the last setup before this. I can't give a night and day feel of the exhaust as I changed tires and Livernois Tuned in the middle of it. Best way to describe is the tone is super deep and bass like but they all at wot on the freeway sounded similar and relatively quiet inside with the exception of a single delta 50 setup video above. Only downfall for all setups (besides 5 mufflers) is cold starts if you live in a super suburb area at 3:00 to 5:00 AM range. I did sound deaden the doors, hatch and spare tire area in the process about 3 setups ago and that also helped. If I had a real sub system and not this under the seat setup in the trunk I can surely say the exhaust doesn't cancel out the subs except the single delta 50 setup video above.

The setups videoed above was
Flowmaster Delta Flow 2.25in Center Inlet X 2.25in Center Outlet 50 Series Muffler 942450 and VIBRANT Performance 1140 2.25" Ultra Quiet Resonator. The flex pipe was some random "anti rattle" 2 piece with bellows setup that you can hear rattle clear as day in the middle video.

The setup I missed to film was
Genuine Ford Front Pipe DB5Z-5G203-A, Custom X pipe, dual in single out faux magnaflow muffler into 2 faux magnaflow mufflers. This actually sounded good enough and was quiet enough on road trips doing turnpike runs with the 5th and 6th gear shuffle but I still wanted dual all the way back. This current setup is a hare louder but not a hastle to drive long distances. I'm going to try to get videos this weekend hopefully. Lack of other people to film sucks.

TL;DR

My goal when I replied way up top in July of 2022 was duals with 3.7 front deleting the factory Y and random squish setup that was a $466 replacement when the flex failed, x pipe, sound good, and no drone. I feel like I accomplished what I went for w/o going to a $2K well established off the self kit just to be that guy to cut it up anyways just to swap components of it out. I'm sure if I went back and looked at the receipts I did meet or exceed any "Bolt On" Sport kit in parts and labor.

 

[AdamWest436]

I still need to grab outside shots, Here is 2 videos both Shell 93 octane. I'll try and grab identical ones now I'm back on E85.

I plan on rigging something up for the extra hanger just to give it some extra support. Your setup sounds pretty good especially after the addition of the vibrant mufflers on top of the flowmaster. Sounds pretty close to stock inside, but a little tone outside

Late to the reply with a whole write up. I just noticed my 2019 has both hangers up front once I took pics from underside and reviewed them.