New 04.5 600 exhaust installed!! Pics

[BApple]

Just got my new exhaust installed on my new 600. Had to replace that nasty kitty and restrictive muffler. I put a Aeroturbine in place of where the kitty would be and replaced the stock muffler with a 51" Donaldson straight thru muffler. That sucker is BIG!! Anyway, I wanted to have an exhaust that was as free flowing as possible but without all the noise to go with it. All I can say, this system is exactly what I wanted. Sound is almost stock at idle, but a blip of the throttle tells you differently. Nothing outrageous, but you can definitely tell something different is under there. At wot, the sound is very pleasant, slightly more loud than stock, with lots more turbo whistle. And no, absolutely positively NO drone at ANY rpm!! Butt dyno also tells me that things are freer flowing. Throttle response seems a little crisper. I'm sure if you wanted a little more noise, you could opt for the smaller Donaldson. For my taste, this setup is perfect. All I need now is to open up things on the intake side (waiting for the PG7 for 04. 5's). Here are a few pics that I took afterwards. I would personally like to thank Dave at Diesel Power Products for his help with this project. Everything fit up very nicely on the install. I purchased the Donaldson thru my local diesel parts store and Dave supplied me with the AeroTurine and other piping. Thanks for your help Dave!! Let me know if anyone has anymore questions about this setup. Here are a few pics of the setup.



Brad

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[AKAMAC]

You really need to get that truck dirty. Your not kidding about that muffler, looks like another fuel tank. Nice work. Mike

 

[Gary - K7GLD]

Does use of that Aeroturbine mean that use of the term "muffler bearings" is now valid?

 

[BApple]

BTW, I will try to get a pic of the cat. for you guys. That thing is holding back this engine as well as that stock muffler. Also, I only had $350 total in this project Be hard to beat that (if you stay with a muffler setup).



Brad

 

[AndyMan]

Looks awesome! Did you reuse any of the stock intermediate pipe? Or did you have new pipe bent by a muff shop, buy new pipe, etc??



Thanks,

Andy

 

[PolarisRMK]

One less kitty under my dodge

I live in Washington State and i was wondering if it was legal to take the big kitty (CAT) out from under my Dodge. and if it is not than how would you get caught if you did? :--)

 

[BApple]

Andyman,



I bought an intermediate pipe from Dave Meheen at Diesel Power Products. The pipe has the correct bend to compensate for the straight thru muffler, instead of the off-center muffler stock setup. I put the aeroturbine where the cat would be then only about 8 inches(basically had to cut the intermediate pipe at the bends) then the massive straight thru Donaldson 51" muffler. If you want to try this setup call Dave. His website is



www.dieselpowerproducts.com



I have given him feedback on this setup so he would know what you need. If you decided on the smaller Donaldson (38" I think) you have just not cut off as much of the intermediate pipe as I did. That would go for any smaller muffler as well.

Let me know if you have any other questions. I am loving this setup so far.



BTW, looks as if I have exceeded my bandwidth on my picture host site. Oh well, maybe I can get some more up later.



Brad

 

[BIG BOB]

I put the 51" Nelson 4" straight thru and then added a 4" x 6" Stainless Steel tip from Rip. It sound really good with no drown and is not much louder than stock.



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[Mark Craig]

"600" exhaust systems

Morning,



Just an FYI, we just got the first packaged systems ready for shipment for the 600 engine. The systems are 4 inch from the cat back with our Spiral Flow muffler and all the "normal" features of our other systems. There is a cat test pipe for those that race and off road as well as a dual system for those that like the looks of duals. We didn't replace the down pipe as it is pretty good already and the amount of improvement is minimal at best, bad for us sales wise but good for the consumer as the prices are considerably lower without a down pipe to contend with.



Mark @ DPPI

 

[TCordero]

BApple,

I am looking to drop the factory muffler on my 04. 5, it seems like the Nelson/Donaldson muffler it an afforable swapout. Was it a simple "cut out and replace" for the 51" muffler or would the 38" be an easier, less involved and expensive swap? Also, can I order the muffler straight from the local freightliner shop?



Thanks,

04. 5, QC, LB, 4X4, 6sp

 

[bmallen]

BApple,



Do you happen to have the part number for that Donaldson muffler? I've found two but I don't know what one will work. P/N M090544 and P/N M085171.



Thanks

 

[Car_nut57]

Great looking system and you installed it exactly the way it should be, with the Aeroturbine as far forward in the system as possible. The Aeroturbine works best with heat and helps to lower EGTs and stop drone which can occur in some systems. We also like the tone of the exhaust with the Aeroturbine and it is available with or without a resonator built in.



Another trick that is simple and enhances exhaust flow is to remove the cast iron elbow from the turbo and smooth the inside surface. It takes about 20 minutes using an abraisive flapper wheel on a die grinder. The idea is that the exhaust gases are spinning at a high rate of speed as they exit the turbo. Eliminating the rough surface inside the elbow helps to reduce the turbulence of the exhaust gases and as they make the transition into exhaust system. If you you don't want to spend the time and effort to smooth the elbow, the Banks down pipe is a direct bolt on that does this for you.

 

[BApple]

TCordero,



The install was pretty straight forward, cut out the stock muffler and cat and fit up the new pieces. You will need a few pipes from Dave at Diesel Power Products to get it to fit up just right, at least that's what I did. Not sure what the smaller Donaldson costs, but the 51" Donaldson cost me about 75$ I think. Bought it from my local Freightliner dealership.



BMallen,



Part number M090544 is the one that I used. 4" inlet-4"outlet on center, straight thru.



BTW, I just added a 5 inch diameter 12 inch long chrome tip , now the system looks as good as it sounds. Also added my PG7 intake and the truck really feels much freer flowing now. Love the sound of my truck.

 

[smokejunkie]

BApple,

Did you get the aeroturbine with the resinator or without?

 

[BApple]

Smokejunkie,



Not sure but I think I got the Aeroturbine with the resonator. Don't think I had an option between the two when I ordered mine. I do remember it looking somewhat like a resonator though. It's still very much a straight thru design either way you go. I can't imagine that the sound of the one with the resonator is much different than the one without the resonator. Just my opinion. I think it would sound great with either. Good luck!!

 

[EEngel]

Exhaust

BApple,



Looks really good. Did you see any drops in EGTs?

 

[SECochran]

I put the 51" Nelson 4" straight thru and then added a 4" x 6" Stainless Steel tip from Rip. It sound really good with no drown and is not much louder than stock.



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i would like info in your cb/ham radio mount

 

[BApple]

EEngel,



Unfortunately, I did not have any gauges on before the install to be able to tell if I had any drops in EGT temps. I can't see why there would not be a drop in the temps, the question would be by how much did they drop. I think anytime you open up the intake and exhaust, EGT's are certain to drop. Would have been nice to do a before and after to really tell, but I wasn't able to do that. :{ Sorry.

 

[BIG BOB]

SECochran,



You have a PM.



Big Bob

 

[JohnnyH]

Quick question for you guys that put 51" mufflers on 04. 5 trucks. I am going to leave my cat in place. Will this setup still work. Besides the muffler, what parts should I get to put the whole thing together. Also, are any of the stock hangers still usable with this system. Thanks.



John