Exhaust question? 5.4
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New User
Joined: Jul 2002
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From: Indian Trail, NC
Exhaust question? 5.4
Hey all, I have a 2003 F-250 5.4 4x4. Im wondering 2 things...
1. What is the exhaust pipe size for my exhaust system?
2. If I cut the pipe behind the muffler, can I just unscrew the clamps in front of it and take it off???
See, what Im thinking is, if I can remove the muffler myself and replace it and leave it single instead of dual, it should be pretty easy. (I think) Just a few adapters and clamps.
Also, if anyone has done this, how does it sound and what muffler did you use? Im looking at either a glasspack or a flowmaster 40 series, and to be quite honest, I want it deep and throaty so Im not worried about it being too loud. Im actually more worried that it wont be loud enough. Thanks in advance for your input!!!
1. What is the exhaust pipe size for my exhaust system?
2. If I cut the pipe behind the muffler, can I just unscrew the clamps in front of it and take it off???
See, what Im thinking is, if I can remove the muffler myself and replace it and leave it single instead of dual, it should be pretty easy. (I think) Just a few adapters and clamps.
Also, if anyone has done this, how does it sound and what muffler did you use? Im looking at either a glasspack or a flowmaster 40 series, and to be quite honest, I want it deep and throaty so Im not worried about it being too loud. Im actually more worried that it wont be loud enough. Thanks in advance for your input!!!
Fleet Mechanic
Joined: Dec 2004
Posts: 1,365
Likes: 6
From: Ketchikan, AK.
you need to cut off the cat (if your state will let you).... they steal all the sound. when i first put on my flowie, with the cat on, it was not much better than stock... then took off the cat, and she finally talks !!
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New User
Joined: Jul 2002
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From: Indian Trail, NC
Originally Posted by Autobahn F-250 Lariat
I have a 40 series but it is not as throaty or loud as i thought it would be 
And mattd17, is there a way to check online if I can cut the cat off? I assumed since its a 2003 that I can't.
Thanks again for the responses!
Fleet Mechanic
Joined: Dec 2004
Posts: 1,365
Likes: 6
From: Ketchikan, AK.
it depends on your states regulations.... i know here in alaska we dont have emission testing, so its legal to remove it. florida was the same way.
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Fleet Mechanic
Joined: Jul 2005
Posts: 1,800
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From: Southern Colorado
It's not technically legal in *any* state to remove the cat - there is a federal law prohibiting cat removal. Also, if you have OBDII emissions, the oxygen sensor located after the cat is not going to like the missing cat.
My exhaust guy cannot legally touch the dual/no cat exhaust system on my unlicensed 1983 Chevy plow truck. To do any exhaust work at all, he would first need to install new cats. So, I cobbled on a set of duals from an old diesel Suburban and left it at that. For him, there's a $50K fine for disabling emission equipment - just not worth it for him. I understand.
Steve
My exhaust guy cannot legally touch the dual/no cat exhaust system on my unlicensed 1983 Chevy plow truck. To do any exhaust work at all, he would first need to install new cats. So, I cobbled on a set of duals from an old diesel Suburban and left it at that. For him, there's a $50K fine for disabling emission equipment - just not worth it for him. I understand.
Steve
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Thread Starter
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New User
Joined: Jul 2002
Posts: 13
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From: Indian Trail, NC
Yeah, thats what I thought too... Im just going to hack off the muffler and pop a glasspack up there. I didn't think I could mess with the cat but it would be nice!
Now I just need to call around and see if anyone has them in stock with a 3" inlet and out.
Now I just need to call around and see if anyone has them in stock with a 3" inlet and out.
Senior User
Joined: Jun 2005
Posts: 110
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From: Louisiana
i hallowed out my rear cat on my little ranger and DAMN it made a difference.
As for a 5.4L in a f-250, my cousin has one and i work with him. After bitching at him to get dual exaust he did but the guy screwed up and put magnaflow. I'm pretty sure his stock exaust was louder. He brought it back a few days later and got it replaced with a flowmaster muffler. BTW it's 1 in, 2 out. It's loud and all but imo, it should sound a lot better for his big v-8. My little v6 has the throaty sound unlike his truck.
As for a 5.4L in a f-250, my cousin has one and i work with him. After bitching at him to get dual exaust he did but the guy screwed up and put magnaflow. I'm pretty sure his stock exaust was louder. He brought it back a few days later and got it replaced with a flowmaster muffler. BTW it's 1 in, 2 out. It's loud and all but imo, it should sound a lot better for his big v-8. My little v6 has the throaty sound unlike his truck.
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New User
Joined: Jul 2002
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From: Indian Trail, NC
well, I hear ya on the cat thing, but Im not gonna spring for a new cat just yet. I've decided to go with a y pipe and 2 2.5 inch thrush glasspacks. Its the same set up I had on my dodge 5.2 and it sounded good so it should be good here also. I was going to install it today, but damn NC weather turned on me!!! 
It was like 73 degrees yesterday and of course today it was freezing out and raining and tomorrow isn't supposed to be much better. (dammit)
Oh well, I'll do it when I can and report back. Also, I can't help but think that the muffler will come off once I use a hacksaw behind it and just undo the clamps in front of it. I know someone said it was all welded, but it doesn't look like it between the cat and the muffler. Here's to hoping!
It was like 73 degrees yesterday and of course today it was freezing out and raining and tomorrow isn't supposed to be much better. (dammit)
Oh well, I'll do it when I can and report back. Also, I can't help but think that the muffler will come off once I use a hacksaw behind it and just undo the clamps in front of it. I know someone said it was all welded, but it doesn't look like it between the cat and the muffler. Here's to hoping!
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New User
Joined: Jul 2002
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From: Indian Trail, NC
Well, I started on the exhaust a few hours ago, and yes, the muffler is not welded all together with the cat. I had to take all the hangers off and then push on the loosened clamps and it came right off. So far, so good with the exception that I broke my only hacksaw blade and now need to run to get a new one. Other than that, no major issues. Also, hehe.... the truck sounds SWEET with no muffler at all!!!! Im almost tempted just to leave it like that, but.... its just a tad bit too loud I think. I'll update again when its done!