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Project Hazey

The space for a tailpipe isn't huge for running a 3" pipe, 2.5" was fairly easy for my local shop to do. The 2.5" is a good step up from 2.25", and remember the resonator, it's not far behind the muffler, in the upward section. It should take them no longer than about 30 minutes to install one muffler and make a tailpipe, they are fast.
 



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Single 3” out you will lose
Low end torque
Stick with 2.5” because no exhaust shops carry 2.75
Good price! Those are 1990 exhaust shop prices usually in 2025 it’s $400 Just to talk to you

I put a 2.5” pipe on my explorer and a 3” pipe on my bronco ii
Both had similar drivetrain setups and exhaust. I could feel the loss of low end power with the 3” pipe from muffler back immediately
 






@410Fortune Thanks, that's kinda exactly what I needed to hear. I figured there was likely some good reason that Ford designed it the way they did, and I'm not in the slightest surprised to find out that line of thought was right. So just to be absolutely sure before spending the money, the Explorer's standard muffler has 2.25" inlets and 2.25" outlet, is that right? I don't exactly have a proper way of measuring that apart from using a C-clamp.

Incidentally, the friendly fellow also pointed out that whatever muffler is on it actually has a dual 2" inlet, with step downs connected directly to them. So, I can imagine that performance can only be improved by swapping this out for basically any thing the right size.

It's gonna be a Cherry Bomb for sure. I thought Flowmaster would be my go-to but looking at the chambered design, I must admit that I am not a fan. I'm still not sure if I want to go Salute or Vortex, but if I go Vortex, I'll definitely let @CDW6212R know how it works out.
 






I haven't heard of the Salute, that must be new. I never liked a really loud exhaust, but a little more than stock and deeper is great, and much different from typical mufflers. OEM's have a special chamber inside which quiets the volume much more than old stuff that relied on size and lots of complicated passages or stuffing. Those Helmholtz chambers should be built into aftermarket mufflers, but I've never seen one yet. I hope to give it my best to attempt to build one as a small resonator.

FYI, bigger exhaust does not lose low end power ... if you correct the air/fuel ratio to provide more fuel. Lowering air restrictions increases air flow, which leans the mixture to some degree. The OEM computers do adjust some, but not enough, not perfectly. If you can tell there is a loss of any kind with an exhaust change, then you have created a lean condition at that point. It isn't a loss of low end power, it's failure to compensate for more airflow.

I'll start my 302 project with a pair of 2.25" tail pipes, then 2.5" mufflers, 2.5" cat pipes, then 1.625" headers. All of that will increase airflow, and I will not run it at any point without adjusting the PCM, the air/fuel. It will go faster at all speeds for every exhaust change. A dual exhaust is not too big for a 302 V8. Stock 302 Mustangs have been factory made with 2.25" dual exhausts since 1985, none had smaller exhaust systems than that. The 302 Explorer has better heads and intake than those Mustangs, same as the 93-95 Cobra 302's.
 






@CDW6212R My Ex being a V6 SOHC 4.0L and with no intentions of making engine mods, I think Jamie was recommending that I keep the exhaust tame to fit the build. In the thread I mentioned finding (but didn't link to) he had recommended a larger exit pipe for the 302's.
 






Yes your truck doesn't need anything special, my 99 is the same SOHC. I push back at anything that keeps suggesting power is lost by going to a bigger tailpipe or muffler. It's a very minor issue, and nobody should be wary about using a larger exhaust pipe. The myths keep spreading, and they need to be stomped out so the next generation doesn't make the same assumptions. If you at some time want a bigger power or exhaust, just expect to need to have the computer tuned a little to compensate.
 






I'm pushing 10 pounds boost and running factory cats @2.5" to the muffler
flowmaster 40 then out the muffler with the factory pipe @2.25"
All factory pipes and no problems and they fit great too
 






I'm pushing 10 pounds boost and running factory cats @2.5" to the muffler
flowmaster 40 then out the muffler with the factory pipe @2.25"
All factory pipes and no problems and they fit great too
So to be absolutely clear before I spend the money, the SOHC 4.0 muffler from the factory has dual 2.5" inlets and single 2.25" outlet? I seem to be getting conflicting information here. I thought it was dual 2.25" inlets and single 2.25" outlet, but I don't have a proper way of just measuring it myself.
 






So to be absolutely clear before I spend the money, the SOHC 4.0 muffler from the factory has dual 2.5" inlets and single 2.25" outlet? I seem to be getting conflicting information here. I thought it was dual 2.25" inlets and single 2.25" outlet, but I don't have a proper way of just measuring it myself.
Ill. Go see if I can find the old muffler and measure
 






All of the muffler pipes are 2.25", any shop can install a dual in one out version sized that way.
 






Ok after the cats everything is 2.25 before the cats its 2.5
According to my caliper
 






@CDW6212R @donalds Thanks to both of you. My muffler guy said 2.25" pipes but he didn't measure or refer to any data sheets, just looked at them and said so, so I thought I'd better check and verify before pulling the trigger. Guess I need to nab a set of calipers, this isn't the first time they would have been useful.

Cherry Bomb 88106CB has been ordered. Will follow up with progress.
 






2.25” downpipes into muffler
2.5” out of muffler

The mufflers I buy typically have dual 2.5” inlet and a single 3” outlet… have to neck down to 2.5” on the exit. The 2.25” pipes usually fit easily into the 2.5” muffler inlets

If you go with single inlet and outlet setup, You should consider spintec mufflers over cherry bombs imo… they are awesome! Well built and cool technology, will outlast the rest of the exhaust that is for
With the spintec they are
Very compact so easy to run two of them next to each other. The cases are thick so. You can easily weld two of them together. I usually run the 2.5” inlet and outlet version
 






@CDW6212R All right, you asked, now you shall receive.

The Cherry Bomb 88106CB utilizes a reversible design, so while Cherry Bomb's official web site lists it as having a single 2.25" inlet and dual 2.25" outlets, this configuration will fit the 2nd-generation Ford Explorers installed with the Cologne V6 SOHC 4.0L. Its body is 16" long by 10.25" wide by 4.25" tall, constructed from steel.

Here I will be comparing the Cherry Bomb 88106CB to the factory muffler on the '99 Sport V6 SOHC 4.0L, which originally had the same exhaust system as the Limited with the same engine, save for a shorter exit pipe due to its shorter wheelbase, as well as to the previous muffler of unknown brand, material, and interior design.

The factory muffler on the Sport is quiet, canceling sounds of all frequencies fairly well. You can definitely hear it when the RPM's reach 2000-3000, and while the sound isn't particularly pleasant to the ear (after 25 years of service, at least), it isn't irritating and doesn't drone between 1500-2000 RPM's. It just sounds like a machine doing work. Startup is like whispering, and idle is quiet with just a tiny bit of growl to it. Revving up in Neutral doesn't make any special sounds.

The unknown muffler on the Limited was decidedly louder than the factory muffler on the Sport. I cannot speak for the differences in sound deadening between the Sport and the Limited, or the differences in interior resonation between a 2-door and a 4-door, but I mean to say that all known controllable factors being equal, the engine could be heard much more loudly inside the cabin at all RPM's than in the Sport with the factory exhaust. The tone was not far different from the factory muffler, although you could definitely hear the higher frequencies more than the lower frequencies as the RPM's reached the 2000-3000 range, and there was a definite drone around 2000 RPM's. Startup was a bit noisier than the Sport, but not obnoxiously so, and this one had no growl (likely due to the lower-frequency cancellation) but otherwise sounded similar to the Sport at idle. Revving in Neutral is not a thing I ever recall doing with this setup. I didn't want to hear it and I'm sure you wouldn't have either.

The Cherry Bomb 88106CB now on the Limited effected a significant improvement in both sound and throttle response. While I have no way of knowing what a factory exhaust system would feel like underneath a 4-door Explorer, or what other design differences were at play between the previous muffler and the Cherry Bomb, I can say with supreme confidence that the 2" inlets on Hazey's old muffler were suffocating her. My driving habits have not changed, hanging between 2000-3000 RPM's on every launch, and she gets up to speed with a lot more gusto now. The Cherry Bomb has a deep sound, as it muffles the higher frequencies more than the lower ones, but it is not louder than the muffler it replaced. It is decidedly not as quiet as the factory muffler. It does deliver on Cherry Bomb's promise that there will be no obnoxious droning sounds at highway speeds, but I won't lie, you can definitely hear it between 1500-2000 RPM's. Startup doesn't announce its presence, but you won't be making any sneak entrances either. Idle is tame, but you can hear that low growl allll the time. Revving in Neutral should be done frequently and without discrimination. The 4.0 isn't a muscle car engine and it never will be, but the Cherry Bomb brings out a little bite from it, really coming to life when you let off the throttle, as you can hear just a slight bit of crackling when the RPM drops.

The 88106CB definitely capitalizes on the low-pitched sounds that the SOHC tends to make, and I can only imagine that the Vortex sound would pair even better with the 302 V8. Having driven with this muffler for 1 day, I'm going to say that all of the impressions I have thus far are good.
 






That sounds good, not quiet, but a low enough volume to not be too obnoxious. My 99 with the SOHC might be similar to that, it's Edelbrock muffler is a little louder than the stock one was. But it wasn't anything special sounding that made me want more or another like it. I have a resonator I had put on too with it, I didn't want to try it without that first, so it was one trip to the muffler shop.

Thanks for that choice on your truck, it sounds like a good muffler for either a stock replacement, or an upgrade if a person was after that. That was the last muffler I wanted to try, before it I put Borla's on my first Mark VII. Those were also a bit louder for what I expected back then, and I figured their top line Pro XS might also be on the loud side.
 






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