I'll start by saying that the Search feature does not work on my computer (aka: phone)... I've tried and it just doesn’t.

I noticed a little extra "burble" from my exhaust today and found a pretty good-sized rust hole at the downstream seam of the giant factory muffler, it probably rusted from the inside-out.

Do you guys have a preferred muffler or after-cat system you like? Without recommendations I'll probably just buy a parts-store replacement, but if there's room for improvement I'll take it.

I'd like a little (or a lot) more aggressive sound, but I'm not expecting "big block w headers" type noises out of a 93 4.9. I have to run through emissions so straight-pipes are out, at least until I GTF outta this town.

Not interested in running duals or anything custom/expensive... just a bolt-in.

Thanks.

 

I run a cherry bomb glass pack on my 4.9L same year, it does okay for sound. Its not as impressive as my friends 78 F250 with the 390FE, but it still sounds decent.

 

Good ol Cherry Bombs are always an option. No problems with the computer?

 

Any sound you're going to get out of a 4.9L is that of a grumpy tractor. That said, the catalytic converter does the majority of the muffling on these trucks so even running without a muffler is not that loud. If you want it to make some amount of noise, run a straight through muffler like a Thrust Turbo muffler. That will flow better than stock and gurgle a little more than stock.

 

GNR22 is right you will never get much sound off of the 4.9L. That being said I wouldn't change my 4.9L for anything else. I had no issues with the computer because nothing was modified with the smog compliance stuff.

Caveat to the no sound thing, you could always go to Clifford's performance buy his performance build kit, and run straight pipes, you will get a beautiful rumble then.

 

X3 on what's been said above. If you still have both factory cats, you really don't need anything more. All I've ever run is both factory cats with straight pipe behind them. It's not unreasonably loud at all.

 

I had the same situation. I put a flow - through glass pack on it, and ran the exhaust STRAIGHT out the back at the bumper. It's quiet inside the cab, and just a little raspy if you get on it. My truck is a 93 with stock 300 straight six. This is not too offensive for most applications. It is really not as loud as I expected it to be with all 6 cylinders going into a single pipe. I think I ran 2 inch or 2 1/4 pipe. I guess my glass pack is about 16 inches long, and you can see right through it.

 

Another note - the only thing I left on the truck was the O2 sensor. Cut everything out and put in a straight through glass pack. No CAT. still not too loud.

 

All good info, thank you.
I'd probably have more "fun" and not save much $$ by going w straight pipe over a glass pack by the time I buy pipe, couplers, and clamps.

I do like the grumpy tractor comparison though. It already sounds like a piece of equipment... just a dull, machine-y hummm. That's okay, because that's pretty much what it is... a piece of equipment. Someday I may get a donor truck and swap in a V8, but that ain't happening for awhile, if ever.

 

If you swap to a V8, you will be retiring one of the best engines Ford ever made. If I had a 302, I would be on my second engine now. I have 2 straight sixes with 300,000+ miles. I put in 6 quarts of motor oil, and 3000 miles later it's still near the full mark. For a time most UPS trucks ran them too. Don't get me wrong - nothing wrong with a V8. But with good care only diesels can run longer than the 300.

 

After rebuilding my truck I cut out the CAT (it was toast) and just ran a single Glass Pac with everything else straight thru... It os not overly loud and doesn't sound bad for a 6... but she runs like a top! I Don't know what the original mileage was because when I bought it the engine had been replaced and the C6 Tranny wa just rebuilt... it had several leaks (which I fixed) but it has started first crank and ran without a single hickup since I put her back on the road.... it's now been over a year and I am getting her painted now.... cn't wait to see what she looks like when she done!

 

I ran 2.5" cat back with a flowmaster muffler on my 95 4.9. The 3"×10" resonator tip makes a good rumble. I personally like mine quiet because drone was annoying on road trips