Note: This article contains affiliate links. If you click on these links and make a purchase, I may earn a small commission at no extra cost to you. This helps support my research and content. Read my full affiliate disclosure here.
If you drive a Ford Explorer ST and want more audible presence, throttle response, or exhaust efficiency, the right cat-back exhaust system can make a visible difference. Upgrading this section of the system affects tone, backpressure, and weight without altering emissions equipment up front.This guide highlights seven shortlisted cat-back options that suit street, sporty, and light-track use for the Explorer ST. We focus on build quality, expected sound characteristics, and how installation and fit affect everyday driving. Read on to see the evaluation criteria we used and practical considerations to help you pick the right system.
Looking for other parts? See all Ford Explorer parts & accessories.
Top Picks at a Glance
| Best Overall The best all-around choice for most situations | Borla 140821 ATAK Cat-Back Exhaust System |  |
| Best Quality Built to a higher standard if you want something more solid | Borla ATAK Cat-Back Exhaust System for 2020-2023 Ford Explorer ST / Lincoln Aviator 3.0L V6 EcoBoost |  |
| Best Budget The cheapest option that still gets the job done reliably | MBRP Armor Lite Cat-Back Exhaust System, 2.5in Dual Rear Exit with Quad Tips |  |
| Highest Rated A top-rated pick with lots of positive feedback | BORLA Cat-Back Exhaust System T-304 Stainless Steel with Dual Black Chrome Tips |  |
| Most Popular A crowd favorite that many people choose with confidence | Borla Cat-Back Exhaust System T-304 Stainless Steel, Black Chrome Tips |  |
1. Borla 140821 ATAK Cat-Back Exhaust System
| Installation Type | Bolt-On |
|---|---|
| Material Type | Alloy Steel |
| Shape | Round |
| Compatible with Vehicle Type | Truck |
This Borla ATAK cat-back replaces the stock rear section with a bolt-on system engineered to deliver a noticeably louder, sharpened exhaust note while retaining a simple install path. It is used as a direct replacement to improve exhaust flow and acoustic feedback during spirited driving, with Borla's tuned internal design producing a crisp, high-performance tone that helps drivers sense engine rpm and shifts. The system is manufactured from alloy steel and includes a dual 4-inch rolled angle-cut tip and 2.25-inch piping, giving a durable, aggressive appearance at the rear. Practical benefits include improved sound clarity, a durable fitted system that bolts on without major modification, and a finished tip that complements a performance truck. Expect a significantly louder and more aggressive tone compared with factory systems, which may be more than some drivers want for daily commuting and could require professional alignment of hangers for best fitment.
Best for: Buyers who want a high-energy, track-inspired exhaust sound and a durable bolt-on system that enhances driving engagement on a Ford Explorer ST set-up.
Less Ideal for: Drivers who prioritize a quiet, near-stock cabin or who need a mild, subtle exhaust note for frequent city driving should consider quieter systems.
- Borla-tuned ATAK sound profile for clear, performance-focused exhaust tone
- Bolt-on installation designed for direct fitment to compatible trucks
- Alloy steel construction for durability and corrosion resistance
- Dual 4-inch rolled angle-cut tips provide a finished, aggressive look
- Significantly louder tone may be intrusive for quiet daily driving
Verdict: Choose this Borla ATAK cat-back if you want a durable, bolt-on exhaust that delivers an aggressive, performance-tuned sound for a sport-oriented Explorer ST setup.
2. Borla ATAK Cat-Back Exhaust System for 2020-2023 Ford Explorer ST / Lincoln Aviator 3.0L V6 EcoBoost
| Fitment | 2020-2023 Ford Explorer ST and Lincoln Aviator 3.0L V6 EcoBoost |
|---|---|
| Material | T-304 stainless steel |
| Tip Style | Quad 4" carbon fiber tips |
| Sound Level | ATAK aggressive sound with low in-cabin drone |
This Borla ATAK cat-back replaces the factory rear exhaust from the outlet back to deliver a much more aggressive, attention-grabbing tone while keeping in-cabin drone to a minimum. Designed for the 3.0L V6 EcoBoost in the 2020-2023 Explorer ST and compatible Aviator, the system uses mandrel-bent T-304 stainless steel with an internal H-pipe in the front muffler to help smooth exhaust pulses and support midrange torque. It bolts to the factory front section for a straightforward install and finishes with quad 4-inch carbon-fiber tips for a sporty appearance. In daily use you get a noticeably louder, sportier exhaust note under load and a controlled idle and cruise character thanks to Borla's ATAK tuning. The package focuses on sound and durable materials rather than weight savings, and buyers should expect a strong, performance-oriented tone that may be too loud for those seeking a quiet upgrade.
Best for: Drivers who want a bold, track-inspired exhaust note and reliable stainless construction for spirited driving on the Explorer ST or tuned Aviator, valuing sound and durability over stealth.
Less Ideal for: Anyone seeking a subtle or near-silent exhaust upgrade or those prioritizing the lightest possible aftermarket components should look elsewhere.
- Aggressive ATAK-tuned sound that amplifies throttle response and engine character
- T-304 stainless steel construction resists corrosion for long-term durability
- Internal H-pipe in the front muffler improves flow and midrange performance
- Bolt-on design fits the factory connection points for relatively simple installation
- Quad 4-inch carbon-fiber tips provide a distinctive sporty look
- Prioritizes sound over weight reduction so it is heavier than some performance options
Verdict: Choose this Borla ATAK cat-back if you want a durable, bolt-on system that delivers a loud, track-focused exhaust note and improved midrange performance for the Explorer ST.
3. MBRP Armor Lite Cat-Back Exhaust System, 2.5in Dual Rear Exit with Quad Tips
| Material | Aluminized Steel |
|---|---|
| Tubing diameter | 2.5 inch |
| Exit | Dual Rear |
| Tip diameter | 4 inch |
| Installation Type | Bolt-On |
This MBRP Armor Lite cat-back is a straightforward bolt-on exhaust built from aluminized steel with 2.5 inch tubing and dual rear exits ending in 4 inch quad tips. It is designed to increase torque, horsepower, and throttle response while lowering exhaust gas temperatures for daily driving and light spirited use. Installation is simple for someone comfortable with basic shop tools since it bolts on to factory hangers and flanges. The aluminized finish resists corrosion better than bare steel, though it is not stainless so long-term appearance may dull sooner. Sound character is expected to be sportier than stock without being overly aggressive for neighborhood driving. Because the system is vehicle-specific, it gives a clean fit and visible quad tips that improve aesthetics. Buyers should note this is a performance-oriented cat-back, not a weight-saving or race-only system, and the material and diameter choices favor balanced power and cost rather than ultra-high-flow performance.
Best for: Buyers wanting an affordable, factory-style performance upgrade for everyday driving who prioritize improved drivability and a sportier rear appearance over maximum flow or track-focused gains.
Less Ideal for: Drivers seeking a lightweight, race-oriented exhaust or those who want a mirror-polished stainless look for long-term finish retention should consider other options.
- Vehicle-specific bolt-on design for straightforward installation
- Aluminized steel construction offers improved corrosion resistance over plain steel
- 2.5 inch tubing and dual rear exit improve torque and throttle response
- Quad 4 inch tips enhance rear styling and presence
- Aluminized steel is not as long-lasting or polished as stainless steel
Verdict: A budget-focused, bolt-on cat-back that gives the Explorer ST a noticeable drivability and styling upgrade without the cost of premium stainless systems.
4. BORLA Cat-Back Exhaust System T-304 Stainless Steel with Dual Black Chrome Tips
| Material Type | Stainless Steel |
|---|---|
| Item Type Name | Catback |
| Compatible with Vehicle Type | Truck |
This Borla cat-back system replaces the factory rear exhaust with a fully welded T-304 stainless steel assembly that is built for long service and a sharper, engineered exhaust note. It installs as a bolt-on replacement and includes dual split rear piping with dual 4" black chrome tips for a finished look. In everyday use it provides clearer acoustic feedback and a more aggressive tone without the rasp or drone some aftermarket systems produce, and Borla advertises a no-drone guarantee. Because it is full stainless construction with welded joints and made in the USA, corrosion resistance and longevity are strong points for owners who keep vehicles long term. Installation requires basic exhaust tools or a shop; this is a vehicle-specific cat-back so fitment must match the intended model. The main compromises are the expected change in cabin sound and the need for professional alignment or hangers if the old hardware is worn, but for drivers who value a durable, well-tuned exhaust note this system balances sound and reliability effectively.
Best for: Buyers who prioritize a durable, factory-quality replacement exhaust that improves sound without frequent maintenance and expect long-term reliability from their performance SUV parts.
Less Ideal for: Drivers who want the loudest possible aftermarket note or who need a universal, multi-vehicle exhaust option should look elsewhere.
- T-304 stainless steel construction resists corrosion for long service life
- Bolt-on, all-welded design for solid fit and reduced leak points
- Engineered Borla sound tuning that emphasizes clear, non-drone tone
- Dual 4" black chrome tips provide a finished, factory-quality appearance
- May require professional installation if hangers or factory hardware are worn
Verdict: Choose this Borla cat-back when you want a factory-quality, long-lasting stainless exhaust that sharpens the V6 sound while minimizing cabin drone.
5. Borla Cat-Back Exhaust System T-304 Stainless Steel, Black Chrome Tips
| Material | T-304 Stainless Steel |
|---|---|
| Fitment | 2020-2023 Ford Explorer ST and Lincoln Aviator V6 |
| Installation | Bolt On |
| Construction | All Welded |
This Borla cat-back replaces the factory mid- and rear-pipe with a T-304 stainless steel system tuned for a clearer, more aggressive V6 note and dual split rear exit with 4-inch black chrome tips. It is a bolt-on, all-welded assembly made in the USA that is intended to increase exhaust flow and give stronger acoustic feedback without adding complex installation steps. Notable features include Borla's tuned chambering for a signature sound and a no-drone guarantee that aims to limit unpleasant cabin resonance. In practice this system will appeal to drivers who want a louder, sportier tone and slightly improved exhaust breathing while retaining simple installation and durable materials. Expect a noticeably deeper exhaust note under acceleration and a factory-quality fit when installed correctly, but keep in mind this is a performance-oriented part so it changes the vehicle sound profile and may be louder at cruising speeds for some listeners.
Best for: Buyers who prioritize a durable, factory-quality performance exhaust and want a stronger, tunable V6 sound with straightforward bolt-on installation for their Explorer ST.
Less Ideal for: Drivers who prefer a near-silent or strictly stock sound profile or who need the quietest possible cabin for frequent long highway commuting.
- T-304 stainless steel construction for corrosion resistance and longevity
- Bolt-on, all-welded design simplifies installation and reduces leak points
- Tuned Borla sound engineering provides a clearer, more aggressive V6 exhaust note
- Dual split rear exit with 4-inch black chrome tips gives a finished, sporty appearance
- Can increase cabin noise at cruise for drivers sensitive to louder exhaust tones
Verdict: A durable, bolt-on stainless cat-back that delivers Borla's signature V6 sound and a factory-quality fit for Explorer ST drivers seeking a louder, sportier exhaust.
Choosing the Right Ford Explorer ST Cat-back Exhaust System: Key Factors to Consider
Build Material and Corrosion Resistance
The tubing and muffler material determine longevity, especially if you drive in wet or salted-road conditions. Stainless steel alloys and aluminized steel have different lifespans and maintenance needs; higher-grade stainless resists pitting and discoloration better over time.
Weld quality, flange thickness, and hanger reinforcement also affect how the system stands up to heat cycling and road vibration. A more robust build reduces the chance of leaks and rattles, which matter for a performance-oriented SUV like the Explorer ST that may see both spirited drives and long highway miles.
Sound Character and Cabin Tone
Sound describes more than loudness. Consider pitch, rasp, drone tendencies at cruising speeds, and how the tone changes with throttle. Some systems emphasize a deep, settled growl while others produce a higher-pitched bark under load. For a daily-driven ST, managing cabin drone is essential to avoid fatigue on long trips.
Manufacturers achieve different tones with muffler design, resonators, and pipe diameter. If you plan occasional track use, lean toward a livelier profile. If commuting is the priority, pick a system that tames midrange resonance while still providing an energetic on-throttle note.
Piping Diameter and Exhaust Flow
Piping size influences backpressure and flow efficiency. Too small a diameter can restrict exhaust and limit high-end power, while too large a diameter can reduce low-end torque and create a hollow sound. Choose a diameter that suits the Explorer ST's engine characteristics.
The routing and bends matter as well; smoother mandrel bends maintain cross-sectional area through turns, preserving flow. Where available, look for systems that document expected horsepower or torque changes based on dyno testing or engineering data rather than marketing claims.
Fitment, Mounting, and Installation Effort
A true vehicle-specific cat-back for the Explorer ST should align with OE hangers, mounting points, and bumper cutouts to avoid fabrication. Check whether the system includes all necessary hardware, gaskets, and clamps. Bolt-on designs reduce installation time and the risk of exhaust leaks.
Also consider the typical install environment. If you or your shop will work under the vehicle, the complexity of hangers and clearances around heat shields and suspension components affects labor time. Systems with preformed hangers and matched flanges minimize additional adjustments.
Muffler Design and Drone Management
Muffler internals and resonators control both output level and in-cabin resonance. Chambered mufflers, straight-through designs, and packing choices produce different behaviors across RPMs. For the Explorer ST, which is used both on highways and spirited backroads, a muffler that limits low-frequency drone while allowing a strong on-throttle note is often preferable.
Pay attention to whether the system uses active valves or passive resonators. Active valve systems can offer a compromise between quiet cruising and loud sport modes, but they add complexity and potential maintenance points.
Legal Compliance and Emissions Considerations
Cat-back systems should preserve catalytic converters and not interfere with emissions sensors. Some jurisdictions have strict noise and emissions limits, and installing a system that alters or removes emissions equipment can create legal and registration issues.
Confirm that the chosen system maintains factory catalytic hardware or is explicitly labeled as compliant for street use. Where sound levels are a concern, look for systems that reference tested decibel ratings or local compliance notes.
How Sound Profiles Differ and What You'll Hear
Cat-back systems change the exhaust note by altering how gases flow past mufflers and resonators. Expect variations in tone, growl, and throttle response depending on muffler internals and piping diameter.
Under light throttle, some systems emphasize a restrained burble while others present a noticeable low-end rumble. Heavy throttle produces the most dramatic differences, often revealing rasp or metallic bark on more aggressively tuned systems.
Think about where you spend most driving time. A system that sounds thrilling on a twisty road may be intrusive on highway cruises if it produces sustained low-frequency drone.
- Deep, low-frequency notes are common with larger-diameter piping and chambered mufflers.
- Straight-through designs often yield louder, more aggressive sound with less backpressure.
- Resonators and tuned mufflers help control drone but may mute some of the sporty character.
Installation Considerations for Home or Shop
Most aftermarket cat-back systems for the Explorer ST are designed to be bolt-on, using factory hanger locations and flanges. Nonetheless, expect variation in included hardware and the need for hand tools or a lift for safe installation.
Corroded factory hardware, tight clearances, and exhaust alignment can increase installation time. If you plan a DIY install, verify that the kit includes gaskets, clamps, or flange bolts and have penetrating oil and anti-seize on hand.
Professional installation reduces the risk of leaks and ensures proper hanger alignment, but a straightforward bolt-on system with matching hangers will often be manageable for experienced DIYers.
- Inspect hanger rubbers and heat shields during removal; replacing worn hangers prevents sagging.
- Use a torque sequence on exhaust bolts as recommended to avoid leaks.
- Check bumper alignment after installation if the tips integrate with the rear fascia.
A Note on Active-Valve and Dual-Mode Systems
Some cat-back systems use active valves to vary flow and sound depending on driving mode. These can provide a quieter cruising experience and a louder sport setting without additional hardware changes.
Active systems add complexity through moving parts and sometimes require electrical integration or a controller. Consider whether the added functionality justifies the potential for extra installation steps or future maintenance.
If you prefer a simpler, maintenance-free upgrade, look for passive systems that achieve the desired tone through muffler design and resonators rather than electronics.
- Active-valve systems offer on-demand loudness control.
- Passive systems are typically lighter and simpler to install.
- Valved systems may require calibration or interfacing with vehicle electronics.
Tips for Matching Exhaust Choice to Driving Style
For primarily street and commuting use, prioritize systems that minimize drone and preserve low-end torque. Look for chambered mufflers or systems with dedicated resonators.
For owners who spend time on twisty roads or occasional track days, a straighter-flowing system with a slightly larger diameter and freer-flowing mufflers will accentuate responsiveness and top-end power.
If you want audible presence without excessive volume, consider systems that offer subtle tip upgrades or tuned resonators to shape frequency rather than simply raise overall level.
- Daily driving: focus on comfort and low drone.
- Sport driving: prioritize flow and throttle response.
- Balanced use: choose tuned mufflers or moderate-diameter piping.
Maintenance and Longevity Expectations
Stainless systems resist corrosion and typically last longer with less visible wear. Periodic inspections for loose clamps, hangers, and gasket leaks keep the system performing and reduce rattles.
After installation, check for exhaust leaks at flange joints and around hanger points after a few break-in heat cycles. Tighten hardware as needed and monitor for signs of flange warping or gasket compression.
If you encounter unusual resonance or rattling, isolating the source to a hanger, heat shield contact, or internal muffler failure helps determine whether repair or replacement is warranted.
- Inspect mounting points after the first few hundred miles.
- Apply anti-seize to bolts if performing future removals.
- Keep an ear out for new rattles or changes in tone over time.
Still looking for the perfect fit?
Select your Ford Explorer configuration to see the most relevant Cat-back Exhaust Systems recommendations
How We Chose the Best Ford Explorer ST Cat-back Exhaust System
We evaluated candidate cat-back exhaust systems for the Ford Explorer ST using criteria that reflect real-world ownership and the vehicle's performance focus. Key evaluation points included build material and corrosion resistance, since the ST sees spirited use and needs durable tubing and mufflers. Sound profile was measured as a qualitative factor, assessing how aggressive or refined the system is across RPM ranges rather than absolute decibel numbers. Backpressure and flow characteristics were considered via available spec data and design features such as piping diameter and muffler internals, because those affect torque and throttle response. Fitment and ease of installation were reviewed from manufacturer fit notes and typical bolt-on designs, including whether hangers and clamps are included. Compatibility with factory emissions equipment and legal considerations were verified to ensure the systems do not require removal of catalytic components.We excluded full-header or turbo-back systems that change forced-induction hardware, and we left out systems without clear Explorer ST fitment documentation. Our shortlist prioritizes systems that balance durability, sound, and drivability for owners who want a practical performance upgrade.
Our full evaluation process is outlined in our review methodology.
FAQ
Will a cat-back exhaust system for the Explorer ST require emissions changes?
Most cat-back systems replace only the rear section of the exhaust and retain factory catalytic converters and sensors. That means they usually do not require changes to emissions equipment, but confirm the product notes to ensure compliance with local regulations.
Can I install a cat-back exhaust myself on an Explorer ST?
Many cat-back systems are designed for bolt-on installation and can be installed by experienced DIYers with the right tools and a safe lift or ramps. However, rusted bolts, tight clearances, or active-valve wiring may make professional installation advisable.
Will changing to a cat-back affect my vehicle warranty?
Impact on warranty depends on the specific warranty terms and the nature of the modification. Typically, replacing only the cat-back does not void unrelated warranty coverage, but any damage directly caused by the aftermarket part could be subject to inspection and potential denial of claims.
How much louder will my Explorer ST be with a cat-back system?
Perceived loudness varies by muffler design, piping diameter, and resonator use. Some systems increase cabin volume noticeably under throttle while others keep cruising noise moderate. Look for manufacturer sound clips or independent measurements when available.
Are active-valve cat-back systems worth it for daily driving?
Active-valve systems offer flexibility between quiet cruising and a louder sport mode, which can suit owners who want both comfort and performance. They add mechanical and electrical complexity, so weigh the convenience against potential maintenance and installation requirements.
Do larger pipe diameters always equal more power?
Not always. Oversized piping can reduce low-end torque on a street-driven Explorer ST, while undersized piping can restrict high-end power. Choose a diameter that balances flow and backpressure for the vehicle's engine characteristics.
Final Verdict
Choosing the right cat-back exhaust system for a Ford Explorer ST is about balancing sound, durability, and real-world drivability. Prioritize materials and build quality for longevity, match muffler and piping choices to how you drive, and factor in installation complexity when planning the upgrade. If you spend most miles in traffic and on highways, emphasize low drone and a refined cabin tone. If you seek a more aggressive on-throttle experience, aim for freer-flowing designs that preserve low-end responsiveness.Focus on the tradeoffs outlined here to make a confident choice that fits your driving habits and maintenance preferences. A well-chosen cat-back can enhance the Explorer ST's character without compromising daily comfort.
Explore More:
- Check out all Ford Explorer parts & accessories
- Explore Cat-back Exhaust Systems Maintenance & Repair Guides
- Explore Exhaust & Emissions
- Browse all Auto Parts
