OK, my final analysis on this muffler:

* Total cost installed for me was about $120. I only put the muffler in & not the whole "kit" because I saw no benefit in the kit. I don't need a pretty exhaust system.
* Noise: I am particularly sensitive to noise which was a huge concern of mine installing this muffler. However, for the most part, it is not noticeable unless you focus on it. Except while traveling slowly with it under slight load at about 1500 RPM - then it begins to blow a low, booming note that I find obnoxious. Normally the rattle from the engine compartment or the road or air noise cover any exhaust noise, but not at about 15-20 mph up a slow steep hill. However, I don't think many people would notice it. Like I said, I am sensitive to such sounds and I don't like it. It's definitely not a show stopper for me.
* HP: Comparing it to my wife's car, it does seem to have a bit more pep in the upper mid-range as the thing really begins to push volume back through the pipe. But, no giant HP gain. Just "some" gain.
* Exhaust brake effect: This does make a big difference and is worth the cost of the muffler just for that. My wife's car does not coast nearly as well as mine does with this new muffler. I'm not sure about overall MPGs yet but anecdotal evidence suggests the in-city driving may be a bit better.
* Would I do it again? Probably. I am hoping all the various mods I am doing will eventualy combine into something really noticeable.

_________________
2005 CRD Limited:
* 245/70/16 Nokian Vatiiva
* Magnaflow
* Kennedy Diesel lift pump
* Custom CCV condensor
* Custom modified thermostat housing w/bleeder valve

2006 CRD Limited (wife's)
* Bone stock

Don't we all... (see signature below!)

- Chris

_________________
Used to own:
2006 CRD Sport
Suncoast TC, Transgo shift kit, Inmotion, ORM, EHM, Magnaflow SS exhaust, Fumoto valve, EVIC added, Hensley TruControl brake controller, Pirelli Scorpion ATR LR-D in spring/summer/fall, FIA winter front and Blizzaks in winter

If I am reading right, you welded the new muffler into your existing exhaust... did you just run a patch of some kind to connect the shorter muffler into the piping?

_________________
2006 Liberty CRD Limited
Mopar engine, transmission, transfer case skids
245/70/16 Michelin Latitude X-Ice (winter)
235/75/16 Firestone Destination ATs (summer)
Thule roof rack, cargo box
V6 airbox mod
Flowmaster 50 2.5 inch muffler
Edge EZ module (set for fuel economy)
SEGR
TDIWagonGuy CCV filter
B99 (summer), B20 (winter)

Yes. Cut out the old muffler and installed the new one with a short extension pipe.
So far so good.

_________________
2005 CRD Limited:
* 245/70/16 Nokian Vatiiva
* Magnaflow
* Kennedy Diesel lift pump
* Custom CCV condensor
* Custom modified thermostat housing w/bleeder valve

2006 CRD Limited (wife's)
* Bone stock

Which Muffler did you use?

Pete

_________________
2004.5 Dodge 2500 CTD 4x4
1982 CX500TC x2
1983 CX650TC x2
1974 W200 Repower with 4BT 4x4 (The Rattler)
2006 Jeep Liberty CRD (The White Whiz)

It is a 2.5" pipe diameter to match my exhaust pipe diameter. (thus getting rid of the small pipe in the stock muffler) I don't remember the exact model number but it was an off-the -shelf version that Schuck's auto parts was selling. I believe Magnaflow described them by the outside dimensions and this one was 4" thick and 9" wide. It is stainless steel but not polished. I called Magnaflow (picked up the phone on the 2nd ring and I went directly to a tech!) and described my application. They said this one would work fine and that there were not any major differences in performance between the various mufflers since they were all straight flow-through. The only difference was the "exhaust note" - which is fine on mine.

This is a rather small muffler - especially sitting next to the behemoth stock muffler. It is very strange that DC put that giant muffler into this CRD. I would imagine it was probably much more expensive to manufacture than something like the Magnaflow - certainly more than twice as much metal in it & more complex tack welding. It isn't really much quieter since most of the noise in the vehicle is from the engine compartment. The only thing I can think of is perhaps the stock muffler is off another vehicle and they had thousands of them sitting around and needed to get rid of them.
------------
Update on performance: Now that I cleaned my MAP sensor, this thing really raps out such that I think the straight flow-through muffler is probably doing some good. My wife has an identical CRD so I can compare everything I change in my car directly and immediately with hers.....and at this point mine is a totally different vehicle than hers. It responds more quickly, is faster, has more torque - and it is also slightly more throaty sounding. I can also hear the turbo a bit more and after the ORM the engine has a slightly more crisp and higher pitched diesel clatter at idle. Hard to describe...but it is like the clatter is less muffled when I unplug the sensor. I ordered the Kennedy lift pump today and have put myself in line for the ORM box. I am slowly going down the check list of mods - hopefully by summer I'll be at the chip programming stage.

_________________
2005 CRD Limited:
* 245/70/16 Nokian Vatiiva
* Magnaflow
* Kennedy Diesel lift pump
* Custom CCV condensor
* Custom modified thermostat housing w/bleeder valve

2006 CRD Limited (wife's)
* Bone stock

If I were going to modify my heartthrob exhaust I would first start by replacing that large restrictive drum of a muffler we have with a stright pipe and leave the cat and other pipes at the 2.5 they are

I just did mine cutout the old muffler and put 2 ½ straight pipe sounds perfect kept the Cat.