On my 2004.5 ram diesel with stock exhaust i want to delete muffler and cat. In doing so i want to add a (aero 4040 or aero 4040xl) in place of the muffler or cat whichever is easiest. Now I want something that definitely sounds a bit better and louder than stock but also dont want it too loud and annoying. And 2nd does it matter where I put it? Put it either where the cat was or where the muffler was?

 

If I remeber correctly, the difference in the two part numbers you have is... the XL has a resonator built in and the other doesn't. I have the non resonator and it's does a lot to reduce the sound coming out of the stacks. I'm sure the XL would be even quiter

It doesn't matter where you put the muffler but, if you bought the cat delete pipe all you need to do is, cut the cat off as close as you can to it's bell. Cut the muffler out the same way. I say cut because you'll have hell trying to get them apart. The clamps compress the metal to where they don't just slide apart. Not sure about your but, mine had a rivot on the turbo side of the cat. I didn't know this and fought for a half houor on it until I just decided to get the sawsall out !

I installed my Aero at the cat and then installed the cat delete pipe behind it to the muffler. Just dry fit everything before you get too far just in case. I have to cut about a 1/2" off the delete pipe.

 

If you dont mind me asking how long is the aero4040 in length compared to the cat (bell to bell)?

 

I just when out into the cold to measure it for you[:@] brrrr :-)

The Aero is 25" long. I didn't measure the cat delete but, it's about 48" long with a offset in it.

 

I saw your post over at DTR. If youo're looking for your truck to sound like a jet.... by all means, get a AFE stage II, remove the silencing rings. For a 747 sound... install a larger turbo. The muffler will have nothing to do with it sounding like a jet. It's going to be louder than stock, it will have a little drone but, you truck will run much better and sound like a diesel.

 

it will sound like a diesel because of the aero or because of the AFE?

 

the muffler. Don't know if yours is like mine but, there a cat, muffler and resonator in the exhaust. It literally took 300lbs off my truck by removing them all and dropped my EGT's by close to 100 degree by removing the cat. There's a lot of restriction there too that got removed. You have to give and take though and by removing everything, you have to take the truck being a bit louder.

 

wheres the factory resonator? in the stock muffler?

 

Sallyman1, why not just start with a muffler delete pipe from Geno's, and then see if you want it louder? I see lots of guys cutting everything out and then complain that its too loud. IMO, start small (and cheap) then go bigger/louder later if you wantwithout having to redo everything.

That is all that was done to mine, it is louder, but doesn't drone on the highway. It's no where near as loud as a straight pipe, but it's loud enough I can enjoy it without pissing off the neighbors every day

 

Super Dave's got the right idea. Start with the muffler delete, leave the cat on,if its too loud add the Aero 4040. I have the Aero 4040, with muffler delete, but I still have the cat on for warranty purposes. Its not tooloud,but if I pull my horse trailer she'll start singing.