The Ford Explorer ST is one of the most exciting three-row SUVs on the market, blending practicality with serious performance. Its 3.0L twin-turbocharged EcoBoost V6 delivers 400 horsepower and 415 lb-ft of torque, but the factory exhaust system is restrictive and quiet, leaving a lot of sound and performance potential on the table.
For enthusiasts who want a more aggressive exhaust note, better performance, and improved turbo efficiency, upgrading to an aftermarket exhaust system is a must. In this guide, we’ll cover the top exhaust brands and different types of exhaust upgrades available for the Explorer ST, including Thermal R&D, a premium performance exhaust manufacturer.
Types of Exhaust Systems for the Explorer ST
Before diving into the best brands, it’s important to understand the types of exhaust systems available for the Explorer ST. Each option provides different levels of sound, performance, and emissions compliance.
1. Cat-Back Exhaust Systems
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What it includes: Replaces everything from the catalytic converter back, including the mid-pipe, mufflers, and exhaust tips.
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Benefits:
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Improved exhaust flow for moderate power gains (+10-20 HP)
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Louder and deeper exhaust note
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No emissions concerns since it keeps factory catalytic converters
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2. Axle-Back Exhaust Systems
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What it includes: Replaces only the rear mufflers and exhaust tips, keeping the factory mid-pipe and catalytic converters.
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Benefits:
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More affordable than a full cat-back system
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Enhances sound without major modifications
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No tuning required
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3. Downpipes (Catted or Catless)
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What it includes: Replaces the factory downpipes, which connect the turbos to the rest of the exhaust system.
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Benefits:
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Significant horsepower gains (+20-50 HP with a tune)
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Improved turbo spool and throttle response
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Available in catted (emissions-compliant) or catless (race use only) options
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4. Full Turbo-Back Exhaust Systems
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What it includes: A complete exhaust upgrade, starting from the turbos all the way to the exhaust tips.
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Benefits:
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Maximum power gains (+40-60 HP with tuning)
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Deepest and loudest exhaust tone
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Ideal for high-horsepower builds
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Top Exhaust Brands for the Explorer ST
1. Thermal R&D Performance Exhaust
Type: Cat-Back & Axle-Back Systems
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Sound Level: Deep and aggressive, but refined
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Material: High-quality T304 stainless steel
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Features:
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Designed for optimal flow and minimal drone
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Mandrel-bent tubing for improved exhaust velocity
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Handcrafted in the USA
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🔥 Best For: Owners who want a premium-quality exhaust with a deep, aggressive tone and excellent build quality.
2. MBRP Performance Exhaust
Type: Cat-Back & Axle-Back Exhaust Systems
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Sound Level: Deep and throaty
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Material: Available in T304 stainless steel, T409 stainless steel, and aluminized steel
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Features:
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Deep, sporty exhaust tone
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Budget-friendly aluminized steel options for cost-conscious buyers
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Easy bolt-on installation
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🔥 Best For: Enthusiasts who want great sound on a budget with multiple material choices.
3. Borla Exhaust Systems
Type: Cat-Back & Axle-Back Exhaust Systems
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Sound Level: Moderate to aggressive
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Material: T304 stainless steel
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Features:
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S-Type or ATAK muffler technology for optimized sound
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No-drone technology, perfect for highway driving
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Lifetime warranty
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🔥 Best For: Drivers who want a balanced, high-quality exhaust with a deep tone and minimal drone.
4. Corsa Performance Exhaust
Type: Cat-Back Exhaust Systems
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Sound Level: Loud and aggressive
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Material: Premium stainless steel
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Features:
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RSC (Reflective Sound Cancellation) technology eliminates drone
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Straight-through muffler design for high-performance sound
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Increased horsepower and improved exhaust flow
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🔥 Best For: Owners looking for a race-inspired exhaust note without excessive cabin drone.
5. SPD Performance Downpipes
Type: Catted & Catless Downpipes
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Sound Level: Significantly louder than stock
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Material: High-flow stainless steel construction
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Features:
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Available in catted (50-state legal) or catless (off-road only) options
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Reduces backpressure and improves turbo spool
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Works best with a custom tune
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🔥 Best For: Those who want big power gains and a more aggressive turbo sound.
6. MagnaFlow Exhaust Systems
Type: Cat-Back Exhaust Systems
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Sound Level: Deep and refined
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Material: Stainless steel
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Features:
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Moderate volume with a deep exhaust note
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High-flow mufflers for increased performance
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Corrosion-resistant materials for longevity
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🔥 Best For: Owners who want a refined, deep exhaust tone without excessive rasp.
7. AWE Tuning Exhaust
Type: Cat-Back Exhaust Systems
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Sound Level: Loud and exotic
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Material: Stainless steel
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Features:
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High-flow straight-through design
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Optional resonator delete for an even louder tone
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Available with dual or quad exhaust tips
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🔥 Best For: Drivers who want a European-style exhaust note with aggressive performance gains.
Choosing the Right Exhaust for Your Explorer ST
Best Exhaust for Daily Driving:
✅ Borla Touring Cat-Back – Provides a sporty sound without excessive drone.
Best Exhaust for Maximum Power Gains:
✅ SPD Performance Downpipes + Custom Tune – Unlocks the biggest horsepower increase.
Best Budget-Friendly Exhaust Upgrade:
✅ MBRP Cat-Back Exhaust – Affordable, easy to install, and great sound quality.
Best Exhaust for Premium Build Quality:
✅ Thermal R&D Cat-Back Exhaust – High-quality T304 stainless steel with optimal flow and aggressive tone.
Loudest Exhaust for an Aggressive Sound:
✅ Corsa Sport or AWE Tuning Cat-Back – Produces a loud and aggressive exhaust note.
Best Exhaust for Track Use:
✅ Full Turbo-Back System (Downpipes + Cat-Back) – Maximizes power and turbo efficiency.
An Exhaust Style for Everyone
Upgrading the exhaust system on your Ford Explorer ST is one of the best ways to unlock better sound, improved performance, and a more exciting driving experience.
Whether you want a subtle sound upgrade, a full race-inspired exhaust, or maximum horsepower gains, there’s an option to suit every budget and driving style. Are you planning to upgrade your Explorer ST’s exhaust system? Let us know which setup you’re considering in the comments below! 🚀🔥
