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Ford F-150/F-250: Cat Back Exhaust System Reviews

Equipping your F-150 or F-250 non-diesel truck with a $1400 exhaust system won't increase your gas mileage and horsepower, but it will give your truck an unmistakable presence every where you go.

By Scott Deuty - November 14, 2014

This article applies to the Ford F-150 and non-diesel Ford F-250 (2004-2014)

A cat back exhaust system is a performance enhancement that replaces the pipes and muffler from the catalytic converter back to the tailpipe. The purpose of the modification is to increase airflow in this portion of your exhaust system. A secondary purpose would be to create a nice exhaust note from an otherwise silent factory setup. As a truck owner, a cat back system allows you to make your truck sound like a truck.

We've included video clips featuring the exhausts from each manufacturer. To be fair, any one of these manufacturers have several cat back kits available. Another kit from them might not sound exactly like the one in the video.

Cat back Exhausts
Flowmaster
Magnaflow
aFe
Borla
Price $550-700 $600-700 $420-650 $600-1035
Material

Stainless Steel

Stainless Steel

Stainless Steel/Aluminized Steel

Stainless Steel
Tubing Diameter 2.5" 2.5" 3"-4" 3" to dual 2.25" out
Sound Mild Aggressive Mild Aggressive
Warranty Lifetime Limited Warranty Lifetime Warranty 2 Year Warranty Limited Lifetime Warranty
Best Quality: Magnaflow

Best Value: Flowmaster/aFe

The common belief is that an aftermarket exhaust system will increase horsepower and improve gas mileage, which in reality isn't the full story. Most cat back exhaust systems will increase your horsepower by an imperceptible amount while leaving your mpg untouched. There are real benefits though -- like the roar of a Ford V8. Another benefit of a cat back exhaust is smoother, faster exhaust flow due to mandrel bent tubing. That means that an upgraded exhaust should make your truck a tiny bit more powerful. The reality is that five additional horsepower in a three ton vehicle isn't going to make a huge difference.

Upgrading to a stainless steel system is a good idea for those in in cold climates where road salt is common. Some systems offer long term reliability in the form of a lifetime warranty. With prices ranging from $400 to $1400, the best option for any truck owner is to shop around. Pricing for exhaust systems vary more at the retailer's end than the manufacturer.

Flowmaster

Price - $550-700
Material - Stainless Steel
Tubing Diameter - 2.5"
Sound - Mild
Warranty - Lifetime Limited Warranty

Flowmaster's exhausts are the second most popular among F-150 owners in the forums. Flowmaster offers exhaust with both stainless and aluminized steel options. Stainless steel is the better choice if you're concerned about rust. People have complained that the Flowmaster system has more backpressure than their competitors, but ultimately the performance isn't really different from that of a stock truck. Both Magnaflow and Flowmaster exhausts cost around the same amount. It's really a matter of preference. Recommended if you want options and prefer the Flowmaster sound.

Magnaflow

Price - $600-700
Material - Stainless Steel
Tubing Diameter - 2.5"
Sound - Aggressive
Warranty - Lifetime Warranty

The Magnaflow system is the most popular option in the Ford-Trucks community. One of the main reasons people like them is their stainless steel muffler. A common complaint regarding their systems is the phenomenon of "Magnadrone." Some of Magnaflow's exhuast systems tend to create a loud, droning hum inside the cab. Some people don't mind, while others find it maddening. In either case, the drone can be resolved with an additional resonator or a different muffler. Recommended if you need stainless steel and prefer the Magnaflow sound.

aFe

aFe Catback Exhuast
Price - $420-650
Materials - stainless steel/aluminuzed steel
Tubing Diameter - 3"-4"
Sound - Mild
Warranty - 2 Year Warranty

The aFe exhaust system is not as popular with F-150 owners as the Magnaflow units or the Flowmasters, but they are well known in the Super Duty Diesel community. Their other parts, like their air intakes for example, are well known and liked on F-150online.com and Ford-Trucks.com. The response to their exhausts on the F-150 has been generally good too. They have exhaust tips with and without the aFe logo, they build systems that come in stainless and aluminized steel, and they tend to sound higher pitched than their competitors. Recommended if you want an aFe exhaust to match your other aFe upgrades.

Borla

Borla F-150
Price - $600-$1035
Material - Stainless Steel
Tubing Diameter - 3" to dual 2.25" out
Sound - Aggressive
Warranty - Limited Lifetime Warranty

Borla exhausts seem to be the favorite in looks and sound. They have a lifetime warranty and as many options for exhuast systems as Magnaflow or Flowmaster. They do tend to cost more than their competitors, however. Recommended if you like the sound of Borla and a life-long warranty.

Pro Tip

Installation time for the typical cat back exhaust system ranges from one to three hours. Note that the muffler size often varies from your stock muffler making it best to buy the entire system instead of trying to use your old pipes.

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