I Made a 2.5l Sound Like it's Screaming America


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So I've been a little busy with this truck, but one of the best things I did to this thing was simple and about anyone can do it.
  • What was on the truck
Essentially the truck had the stock 2 or 2.25 pipe exhaust on it, until I actually got under there and realized somebody deleted the cat already.
  • What did I do to the truck
Everything past the cat was taken off, the old muffler and about 6-7 ft of pipe was thrown away​
Welded the muffler directly to the 2.5 pipe that replaced the cat​
On the other side of the muffler, I welded about 21/2 ft of 2.5 ID straight pipe with a 45 angle cut welded to another pipe with the same cut that i pre-welded to make it easier to manage under the vehicle that leads the second pipe right under the flaresides foot step​
Put a screw-on stainless tip with the same 45 degree cut and positioned it flush with the body and fired her up​
  • The results
    • Low Rumble tone
    • Quiet Idle, Loud when you get up on it
    • Better gas mileage for sure
    • Opened up the shift timing a bit: 1st 0-15; 2nd 15-30; 3rd 30-50; 4th 50-70; 5th 70-ect.
    • Looks badass
    • Cost $40 all together
  • What I used
    • 10 ft of 2.5 ID exhaust pipe (not SS) - $7
    • Thrush Welded muffler with centered outlet and offset inlet to recess it more up in the under-body - $32
    • Exhaust rubber bushing hangers - $5
This took about 3 hours considering you measure twice and cut once. If there's any questions I'd love to answer them, if you want pictures/videos let me know, thank you guys.
 


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91stranger

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I put that Thrush Welded muffler on my 3.0 and it sounds WAY better than stock. Mine still has the cat but just replacing the muffler with a more open one made a world of difference. Mine is like you said, nice low tone at idle (mine sounds like a v8 when walking by the exhaust at idle) and it has a slight roar when getting on it. Much better air flow than the stock muffler for sure. I wouldn't recommend cutting off the cats though as it is illegal.... Some states are REALLY strict about the cats laws so to each their own.
 
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I put that Thrush Welded muffler on my 3.0 and it sounds WAY better than stock. Mine still has the cat but just replacing the muffler with a more open one made a world of difference. Mine is like you said, nice low tone at idle (mine sounds like a v8 when walking by the exhaust at idle) and it has a slight roar when getting on it. Much better air flow than the stock muffler for sure. I wouldn't recommend cutting off the cats though as it is illegal.... Some states are REALLY strict about the cats laws so to each their own.
Kansas doesn't have emmissions test 😉
 

Dirtman

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So friggin big!
My credo
Give me money.
But... the 2.5 is German...
 

Dirtman

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So friggin big!
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They were originally designed and built in Germany in the 70's (which is why they are metric). :icon_cheers:
 

snoranger

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It doesn't even sound American... 2.5 LITER.
Try calling it 152 cubic inch.
 

Dirtman

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So friggin big!
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Or 507 teaspoons!
 

sgtsandman

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It has a cast iron block, a cast iron head, and a cast aluminum oil pan. And they use the engine for industrial applications like generators. How more robust and American can you get?
 

snoranger

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It has a cast iron block, a cast iron head, and a cast aluminum oil pan. And they use the engine for industrial applications like generators. How more robust and American can you get?
So it overweight and doesn’t move much...
 

sgtsandman

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So it overweight and doesn’t move much...
It is a heavy S.O.B. You should have seen the engine stand flex when I mounted the thing to it and let the tension of the engine puller. It took FOREVER to warm up when it was cold too.
 

racsan

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ive had (3) 2.3 lima’s, every one of them takes forever to warm up. I guess boring them out to be a 2.5 didnt help that. They are the only non-interference 4 cyl that I know of. the dual plug heads after ‘89 seem prone to cracking around the valve seats. ive wondered if the 2.5 feels any more powerful than the 2.3 it replaced. Ive drove a newer 2.3 (mazda engine) and wasn’t impressed, it was in a reg cab shortbed with a manual and 3.73s, my 94 2.3 longbed with cap & bigger tires felt alot more responsive.
 

sgtsandman

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I’ve driven a newer Ranger with the 2.3 that replaced the 2.5. I’ve never driven and older model with the 2.3 the preceded the 2.5. The newer was ok. Nothing to write home about. Same with the 2.5 once the proper gearing was behind it.
 

Dirtman

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So friggin big!
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Give me money.
I like my 2.3 duratec... it's not exactly peppy but gets good mileage and definitely moves better than the lima. :dunno:

I do have 4.10s and an auto with a shift kit though which help alot.
 


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