Aero Turbine Mufflers

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

Well, I was convinced by retmil46's glowing testimonial. I ordered an Aero 2525 today. Should be here the end of next week. Looking forward to scrapping the OEM muffler. Hoping the resonator on the CRD already is enough to keep it quiet enough to travel highway without a lot of droning.

oldnavy · **Posted:** Wed Dec 21, 2005 7:51 pm

Mine didn't have a resonater with stock system, just a muffler. I don't think you will have any problems.

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

I was going by the FSM on pages 11-7 and 11-8. They show the down pipe from the turbo, feeding a catalyst, then a foot later a small resonator, just before the muffler. I'll have to look at the CRD in the morning to see if the FSM matches whats on the vehicle. As long as it's close to the current sound levels I'm happy.

oldnavy · **Posted:** Wed Dec 21, 2005 8:19 pm

On ours after the CAT was just the connecting flanges.

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

From looking under the CRD, what I thought was the CAT was the resonator. The resonator is larger in diameter - the CAT is about the same size as the exhaust pipe - at least in the FSM. I'll know for sure once I get a good look at it in daylight. The FSM shows the resonator being about 2 inches in front of the muffler flange.

breakerbacker · **Joined:** Wed Dec 07, 2005 1:23 pm **Posts:** 76

The large diameter, short item before the flange is the cat. Before that is a flexible section of pipe that is braided. There is no resonator in the crd exhaust system.

Greg

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

Interesting - the FSM has it wrong then. It shows the short flexible section as the CAT. Its listed on 11-7 as item 2 in the drawing. Note how the larger diameter device next to the muffler flange isn't even labeled.

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

That thing is shiny (very high trinket value points)! Plus, you can look in either end and it's straight through!!! Hope to get it installed this weekend.

CATCRD · **Posted:** Thu Dec 29, 2005 9:07 pm

You can see right through it? How is this better than a straight pipe, other than lower noise? Seems to me if we're talking about lowering backpressure behind the turbo, the only thing better than a straight pipe would be an even bigger straight pipe.

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

It has two chambers, one inner, that goes straight through, and the outer, with a nozzle-like aperature that separates the exhaust flow. The www.aero-turbine.com site has a video showing how its built. They also have some sound recordings of different diesel and gas vehicles with the running. A recording of a Cummins 5.9 diesel sounds pretty good.

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

I dropped it off at the muffler shop today at lunch - hour later, it was done. Old muffler was not sooted up but was black inside. Man the factory muffler has some really tiny holes inside the input pipe...the pipe inside is smaller than 2 inches, maybe 1.5 inches in diameter I'm guessing. What a baffler!

Initial impressions - idling, lower exhaust tone. Sounds good. Noise level about the same as stock. You have to listen to hear it - its not loud at all. Outside at the tailpipe, a richer note. Inside, pretty quiet. Impressive for a straight pipe on the center core! Acceleration - much faster turbo spin up, especially at 60 - 85 mph. Acutally sounds quieter on the highway and cruising than the stock muffler to me! I really noticed the difference when revving hard - it revs much, much faster and reaches speed quickly. I only had time to check it out on the way back to work so I'll try it out this weekend and see how it does. I did notice that even while I was climbing some grades, the engine wasn't working hard at all - breathes much easier.

I am so glad I heard about this idea - thanks retmil46.

PS - muffler guy shook his head when he looked at the 2525 before installing it and could see straight through. He looked really surprised when he finished and started it up - like maybe he was expecting more noise?

wenied · **Joined:** Wed Dec 21, 2005 4:01 pm **Posts:** 107

What's the benefit of this over a 25 dollar glass pack?

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

Not having used a glass pack on a CRD, I can't say. I have heard straight pipe, and its not good. Clearly, something in the Aero design is quieting the exhaust tone while reducing back pressure. All the glass packs I've seen usually sound louder than stock, and end up eventually blowing out the insulation and getting even louder over time. There is nothing inside the Aero to blow out! Aero-turbine claims to create a vacuum with their jet nozzle design and thats supposed to help increase power and reduce EGTS... but unless someone compares the 2 designs, I don't know if a glass pack is just as good or not.

If you're feeling experimental, why not give some glass packs a try and let us know?

wenied · **Joined:** Wed Dec 21, 2005 4:01 pm **Posts:** 107

I've been running a glass pack after the cat on my GMC's old 5.7L v8 for 7 years. It's not really loud at all and I love it. I'm think I'll be the guiney pig and have the muffler shop slap on a 4" glass pack tomorrow morning!!! It's 2.5" inlet and outlet. If i have time to take it there tomorrow I'll make a post about the sound level and what not.

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

Excellent!! It'll be great to know how they do. I took some sound readings with my Extech sound meter before I installed the Aero. I'll check them again and see what the actual difference is this weekend.

JCL_05_CRD · **Posted:** Fri Dec 30, 2005 4:10 pm

I am excited about all this muffler talk. I didn't know previously that the muffler was of the 2" variety. Turbo's love to flow, so I can see where uncorking the restriction can only help. I am leaning toward Magnaflow, but like others have said, it doesn't matter as long as you get rid of the stocker.

Ripple · **Posted:** Fri Jan 13, 2006 8:33 pm

this list is great, I learned more in one day here than I have reading for weeks elsewhere!!!

I didn't know about the muffler trick till today, I am definitely going to install high flow muffler. I have a 3" in/out mac stainless muffler on my other turbo car (homemade system on a 3.2L gasser v6) and like it so much I'll have to get one for the libby too.

can anyone see the benefit to doing a 3" cat back? I only have 1900 on the clock and :ashamed: have never jacked it up to look underneath. too many taurus SHO's in the garge...

oldnavy · **Posted:** Fri Jan 13, 2006 9:17 pm

Just do like I did, just crawl under the Libby. :wink:

milou_1968 · **Posted:** Fri Jan 20, 2006 11:56 pm

Ranger1, can you take a picture of the aero installed please. Thank you

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

Sent you a pm... I don't have a site to post pictures on.

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