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I did a simple & inexpensive modification to my 2002 Escape exhaust system this weekend. I was unimpressed with the sound as well as the restrictive look of the resonator (the huge rectangular muffler looking thing located just downstream of the CC) so I completely removed the exhaust from behind the CC (catalytic converter). The exhaust of the escape behind the CC has two major components. First the resonator and secondly the muffler which is located approximately 12 inches from the exhaust tip. I first looked at the muffler and noticed that it was very nonrestrictive. I could shine a light completely through it. It reminded me of an old glass-packed muffler. Then I inspected the resonator and found that it was full of restrictive material, small cavities and a cross-work of channels designed to deaden the sound of the exhaust. It looked very inefficient to me, so I cut it out of the system with a saws-all. The gap I created in the system between the CC and the flanged connector pipe that attached the factory muffler-tip was about 20 inches. I went down to the local auto parts store and found a Thrush performance muffler which had as interior very similar to the stock exhaust tip. I’m sure some of you guys have seen them before. They are the red cherry-bomb looking deals. I bought one that was 22 inches long and had a 2 inch ID inlet and outlet. Then, I simply clamped it in place into the vacated opening I made when I cut out the resonator. I am very impressed with the sound. It has a mellow tone, but is not loud. Before I couldn’t tell that the engine was running from the exhaust. Additionally, I just returned from a 700 mile round trip and found that I went from 24 MPG to 26MPG. That’s not bad. The total conversion took about an hour because I took my time and the cost was a measly $30 and that included two 2 inch muffler clamps and a can of black high-temp paint. I have a buddy with the Gibson exhaust kit on his 2001 escape and he is pissed that mine sounds better, is lighter and cost about $200 bucks less.
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I hope some of you try it out.
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2002 Escape XLT, 2WD, 3.0L
K&N, Mobil One 5W30
76,000 trouble free miles
The Zoom "cherry-bomb" from Advanced Autoparts cost about $19.00
I've put several thousand miles on this mod and it is very solid, sounds great and I've been consistant with the increase in fuel economy. (Hwy 25-26 MPG)
The beauty of this mod is that it doesn't prevent you from going back to a stock cat-back again, or to a pre-fab aftermarket cat-back system if you want to in the future.
[QUOTE=nieking] the CC has two major components. First the resonator and secondly the muffler which is located approximately 12 inches from the exhaust tip. I first looked at the muffler and noticed that it was very nonrestrictive. I could shine a light completely through it. It reminded me of an old glass-packed muffler. Then I inspected the resonator and found that it was full of restrictive material, small cavities and a cross-work of channels designed to deaden the sound of the exhaust.
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I hope some of you try it out.
After the Cat comes the MUFFLER then the RESONATOR is last......The reasonator can be seen thru because it doesn't MUFFLE sound it has a chamber that makes the sound resonate before coming out (changes tone not loudness) The muffler is the one with all "The cavities and cross-work of channals" thats what muffles the sound. Did you take both out? You can eliminate resonators without any drawbacks (did it for years).I took mine off my "05" and put in a straight pipe cause it hit my A/Mkt hitch and the rattling drove me up a wall.........didn't see nada in MPG and very little sound (full throttle).
You are correct STU4NOW. I stated it backwards. I did replace the muffler with the Zoom and kept the stock resonator in place. 98K miler now and it is still running strong.