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Old 02-24-2012, 02:08 AM   #1
MIMF
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Oversized exhaust system

The last several days, there has been some discussions concerning higher fuel prices in this forum and of course, all over the media. For along time, I have been thinking about what an over sized exhaust with low restriction muffler might do to increase fuel mileage and efficiency.

Back in the mid and late '90s, I had a heavy half GMC with the good old 350 in 'er. When the exhaust rotted and needed replaced, I had a 3" diameter exhaust system complete with lower restriction muffler installed that really brought that old 350 alive! I immediately noticed a "throatier" sound that was in no way objectionable in the cab. At least DW never said anything about it but, it was also notice that at lower RPM ranges, she seemed to have a little more torque. There was also, about a 2 mpg gain at highway speeds.

Does anyone have any advise and experience in doing this to their Duramax? I have no interest in chipping or reprogramming because, I do not want to break anything.

Thanks, everyone.
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Old 02-24-2012, 02:16 AM   #2
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I have read that a larger exhaust will help out. Some vendors offer a programer, a better air intake and a larger exhaust system as a complete package for improved performance. I installed a K&N air filter and will not do anymore to my truck.
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Old 02-24-2012, 02:44 AM   #3
1retired06
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I have seen custom exhaust systems on GM,Ford,and Dodge. Sounds cool and runs better. However, for Ford, voids the warranty. I recently had a buddy who had warranty work done on his truck, and the dealer required him to remove his custom exhaust and replace with a stock exhaust before they would do the work, this despite pushing it up the Ford chain with no success.
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Old 02-24-2012, 03:49 AM   #4
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Of course if you do this when you need to replace the system anyway the warrantee period should be a long way behind you.
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Old 02-24-2012, 04:44 AM   #5
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This is just my experience on my ole Powerstroke. I installed a Banks 4" stainless exhaust from the turbo on back. It did lower the exhaust temps pulling hills and there was a bit more seat of the pants feel of power. What minimal increase in milage there was would never pay for the cost of the system for the miles I drive each year. I was mostly interested in reducing the exhaust temp when the boost was high. I think the regeneration issue with the new exhausts will be the sticky point refering to the previous post.
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Old 02-24-2012, 05:12 AM   #6
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Dodges still don't use DEF so for us changing the exhaust probably wouldn't matter. I'm going to ask the dealer when I get home. If I can find something out I'll post it.
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Old 02-24-2012, 07:26 AM   #7
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I put a K and N air intake and a 4 inch Banks exhaust and Monster muffler on the truck and noticed a big difference. The engine likes all the extra air flow.
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Old 02-24-2012, 07:39 AM   #8
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Thanks for the feed-back, guys. My truck is old enough that I'm not concerned about any warranty issues, regenerating or, urea. I already have the K&N on top but, am trying to determine if there would be any further gains with the exhaust. Like most of you, I hear and read that these diesels do seem to like being able to breath. Heck, I'd still be happy if all it did was increased torque. And, we all know that torque is the key!

Keep the ideas and suggestions coming.

Thanks.
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Old 02-24-2012, 07:57 AM   #9
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I also added a Banks Big Head waste gate actuator. It keeps the turbo engaged just a bit longer. I noticed the extra power from that also.
When I did the Banks exhaust, I added the Banks exhaust brake.
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Old 02-24-2012, 08:18 AM   #10
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Changing the exhaust for a larger size won't noticeably help unless you get rid of the catalytic converter. The converter is the choke point in the exhaust system, but of course we all know that removing it is a Federal offense with a fine of $2,750, plus any state or local penalties. Also, some aftermarket exhaust systems have a reputation for causing a droning noise in the cab at high speeds that can drive you nuts.
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Old 02-24-2012, 08:57 AM   #11
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We have an 05 GMC 3500 D/A- We added a 4 inch exhaust system, an airbox by AFE and a Diablo control unit- The result is one strong truck- Mileage increase is minimal but the increase in performance has been well worth the expense- JMHO- Don
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Old 02-24-2012, 09:09 AM   #12
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And if I may add... Going larger diameter, the pipe could easily start hitting the truck frame where it's already close transferring the rattles throughout.

I had the dealer change the exhaust when I got the truck and was going to go with a 5" pipe but the DEALER recommended I stay with the 4" because it was close to the frame in a couple of places.

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Old 02-24-2012, 09:13 AM   #13
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NCFishers: Since you now own stock ($$$$) in Banks with all his products (jesting here), other than obvious power increase ... did you really seen any appreciable fuel mileage gains?
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Old 02-24-2012, 09:30 AM   #14
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I saw a slight increase in fuel mileage but more importantly, an increase in power and I could feel the engine breathe easier. My '03 has no catalitic converter and no DEF. The stock exhaust was 3 inches and the Banks is 4 inches. I did the installation myself and it was rather easy.
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