Ever since I got a 5-Star tune and a free flowing air filter element, I've been thinking of trying to upgrade my exhaust. I've got a 2002 E350 with the 5.4 and I've been told the 5.4 motors respond well to a cat back exhaust, but most everything out there sold as a kit is made for the trucks. I don't want a lot of drone or noise, close to stock but better flowing is my goal, and my OEM muffler is about toast anyway. Has anyone used the Walker Quiet Flow that Summit sells? I do have access to a cheap, good old fashioned muffler shop that will fabricate up anything I want, but I'm not looking to go full duals or anything. The mufflers they have sold me before (Dynomax, Flowmaster) have been way too loud, last time on a 460 van but also on trucks I've had.
Anyone know the stock pipe size on the 5.4 vans? If it's not quite 3", I was thinking I could go cat back with 3" and a Walker quiet flow muffler. I'm thinking I will keep the stock cat. I don't have emissions here but don't want check engine lights, strong smell, or any of that either since we camp and idle a lot with this van.
Yes I know there are tons of threads on exhaust systems, but I haven't found anyone who has the found a fairly quiet system for a 5.4 van.

thanks

 

I would contact these guys.....
www.diamondeyeperformance.com they say Gas & Diesel so you never know... worth a shot .....

 

I'm fairly certain 5-star only recommends upgrading your y-pipe on most 5.4s. Give them a call and ask.

 

FWIW. I put a Flowmaster 40 on mine and yes there is some drone at certain RPMs. But at 60-65 MPH, ie. 15-1700 RPM, it's not too bad. Closer to 2000 it's pretty annoying and then at 2300+ it quietens down again. I've read the the tip has a lot to do with noise, but haven't investigated this for myself. After looking at many Y pipe pictures and comparing to my own, I'm pretty sure there were changes through various years. Just my 2 cents.