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Old 05-26-2010, 01:02 AM   #1 (permalink)
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Stock Exhaust size?

I have a early 2004 Dodge 2500 Diesel 6spd 4x4. I jus ordered and Aero4040XL to replace my stock muffler with. I have a completely stock exhaust. Can anyone tell me the stock exhaust size before the muffler? Some say 4" and some say 3.5" and i cant tell exactly since i havent gotten the muffler in so i havent taken my old one out. Also how would anyone recomend to mount the Aero in place? ANy suggestions or info would be greatly appreciated. thanks!
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Old 05-26-2010, 01:08 AM   #2 (permalink)
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on mine the downpipe was 3.5 then it turned into 4 all the way back. so i think the stock muffler is 3.5" in and 4" out.
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Old 05-26-2010, 01:12 AM   #3 (permalink)
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mine is 3.5" in and 4" out the muffler
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Old 05-26-2010, 10:09 AM   #4 (permalink)
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If its an early 04 then its 3.5 in, 4" out. If its a 04.5 then its 4" in/out.
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Old 05-26-2010, 11:29 AM   #5 (permalink)
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my words exactly!!
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Old 05-26-2010, 08:51 PM   #6 (permalink)
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Look on your valve cover sticker. If it says 325 HP, than it is 4" in and out, because it is an 04.5. If it says something less that 325, than it is an early '04.
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Old 05-26-2010, 09:12 PM   #7 (permalink)
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Its a 305.
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Old 05-26-2010, 09:13 PM   #8 (permalink)
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Originally Posted by dmolson92 View Post
Its a 305.
Then its 3.5" in and 4" out.
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Old 05-26-2010, 09:17 PM   #9 (permalink)
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Okay so i have the Aero4040XL. And we have a flo pro 4" downpipe for an early '04. Is it worth replacing the downpipe and then payin the muffler shop to run 4" from the downpipe to the new muffler?
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Old 05-26-2010, 09:24 PM   #10 (permalink)
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Okay so i have the Aero4040XL. And we have a flo pro 4" downpipe for an early '04. Is it worth replacing the downpipe and then payin the muffler shop to run 4" from the downpipe to the new muffler?
I would say its probably worth it.. should help a little with EGT's.
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Old 05-26-2010, 09:25 PM   #11 (permalink)
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Do you have any idea how much that might cost me?
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Old 05-26-2010, 10:11 PM   #12 (permalink)
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Not sure... I wouldn't think more than 20-50.. Do you have a way to hook up the Aero already since the aero is straight thru and the OE is offset enter/exit?
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