Resonator and muffler replacement

Topic: Resonator and muffler replacement (Read 12582 times) previous topic - next topic

Re: Resonator and muffler replacement

Reply #100 – May 17, 2012, 01:54:52 pm

Jerry, I am not familiar with that model muffler at all, only know the best results are from a resonator, not from a muffler. A resonator is wide open, as in you can look through it, mufflers tend to have many baffles and are more concerned about noise not performance. I would assume your new muffler would be a better bet than the original, but not for performance.
That is my opinion
Dave M

Re: Resonator and muffler replacement

Reply #101 – May 17, 2012, 02:10:18 pm

The aero is basically a straight pipe, had them on my 89 OREG

Re: Resonator and muffler replacement

Reply #102 – May 17, 2012, 04:01:32 pm

I did a quick web search. It appears that the Aero Turbine 4040XL is a muffler, rather than resonator. The company also made resonators.

I could not find a company web site. It appears that the company folded, but many devices are still in the supply chain. I did find many advertisements for Aero exhaust products. Some of the advertisements suggest combining an Aero muffler and an Aero resonator.

Your results and mileage may vary.

Re: Resonator and muffler replacement

Reply #103 – May 17, 2012, 04:13:19 pm

Generally, performance is difficult to determine unless one is very in tune with his machine, if not really in tune with it, a 200 hp increase would go unnoticed in many cases.
Again my opinion from experience
Dave M

Re: Resonator and muffler replacement

Reply #104 – May 17, 2012, 08:44:57 pm

From what I can find out about Aero, there is a new company Tecexhaust that has taken over from Aero.
Home page

Re: Resonator and muffler replacement

Reply #105 – May 17, 2012, 11:35:43 pm

This is what I bought. Aero Turbine Exhaust AT4040XL 4040XL Muffler They call it a resonated muffler, whatever that might be. You can look straight through it. There is a doughnut like ring at the front of the inlet with a 3" hole in the middle, so some of the exhaust goes straight through, and some of it passes around the "doughnut" and through louvers in the tube that supports the ring. The tube with the ring and louvers is supported by being welded in place at the outlet end of the muffler. My opinion is that in this installation most of the muffling is done by the turbocharger.

Re: Resonator and muffler replacement

Reply #106 – May 18, 2012, 08:57:01 am

Has anyone tryed the resonator route on the 6V92TS's as yet ?

Re: Resonator and muffler replacement

Reply #107 – May 18, 2012, 01:18:06 pm

Grapevine has it that they are really loud. We use the Jake full time around here and don't want trouble. You know what it's like here. I was thinking of a 5" in/out with a 44" length. Stock muffler for big rigs I think.

Dave probably knows better than anyone with his MCI experience. Dave?

Pierce

Re: Resonator and muffler replacement

Reply #108 – May 19, 2012, 10:14:00 am

Quote from: Bill Chaplin – May 18, 2012, 08:57:01 am

Has anyone tryed the resonator route on the 6V92TS's as yet ?

Bill, my new diesel mechanic in NAC said don't do it with the 6V92. It will run you out of the coach. He claims that he knows this from experience. Keep in mind that our current plumbing is large enough you can walk through it compared to those dinky little stock Cummins exhaust systems.

Just Joking!!!

Re: Resonator and muffler replacement

Reply #109 – May 19, 2012, 05:02:58 pm

I took your adviced and changed our band clamps to 5" muffler clamps. . .

One photo shows the rear centering adjustment and the other photo shows the muffler clamps holding onto the hangers. Our OEM muffler top framework has been extended rearward so we can have a new attachment point to support the muffler pipe.

I still want to wrap the muffler tail pipe where it is close to our air intake pipe.

Re: Resonator and muffler replacement

Reply #110 – June 08, 2012, 05:57:03 pm

Ours is 90% finished with the Aero 5050XL. The new chrome exhaust tip is due in Monday (normally something they stock, but just our luck they were out), so we have a straight 5" pipe as a temporary solution.

Grrrrrrowwwwllllll

Nice, throaty sound of power! Steve can tell you how it drove, I can only report on the sound. Sure does seem like a lot more airflow coming out that tailpipe...

Inland Truck in Denton did a great job, but of course we pretty much gave them the parts they needed along with a photo tutorial, both thanks to Barry B's "proof of concept" on an '03.

That part of the engine compartment looks vast and vacant now, and great access to the start batteries.

Michelle

Re: Resonator and muffler replacement

Reply #111 – June 08, 2012, 06:47:37 pm

Here are a few pics of the new install. Thanks again to Barry for doing the leg work on how to get this to fit in an 03 w/tag

The parts we used were all Donaldson exhaust parts, we got them all from Filter Products - equipment parts - Donaldson, Baldwin, Des-Case, Wilson, They had the best pricing I could find, plus they worked with the non commercial user

The site is not much visually, you basically need to know your part numbers and enter them, most things you can just buy one of, some small parts only by the case.

Anyway here is what we used on our coach:

DONALDSON      P207365   1   ELBOW 90-5",ALUMINIZED
DONALDSON      J190025   1   45 DEG ELBOW
DONALDSON      X007785   4   SS SEAL CLAMPS
DONALDSON      J000232   2   GUILLOTIN CLMP,DBL SDLE 5"
DONALDSON      P224515   1   SS FLEXTUBE FIVE INCH X 15" (cut down as needed to make things fit)
DONALDSON      P206526   1   PIPE HANGER
DONALDSON      P207283   1   STACK STRGHT 5"X18" ALUM 18" (just for alignment and temp tailpipe)

The most expensive thing was the SS flex @ 40.75 for 15 inches ... this particular flex is a heavier gauge stainless material over standard flex and has a 12 month/120,000 mile warranty (onhighway vehicles only). You could save some money here and get regular SS flex or even non SS flex.
The next most expensive thing was the 5 stainless seal clamps, again you could save some money with non SS or just use Guillotine Clamps (for the non flex joints).

The "resonator" in this case was a Aero Exhaust Resonated Turbine 5050XL Series Performance Muffler. Its 5" in/out, 7.5" overall diameter, 30" long. The tailpipe is currently straight out the back while we wait on the curved tip to arrive, and standing 6 feet behind the coach while its idling the exhaust airflow is quite strong

Here is the marketing blurb on the aero series
http://youtu.be/iDTTOa77efs

Certainly the noise level is up somewhat from where it was, but nothing that was offensive, more throaty is the best description and the turbo did spool up faster. Although backing up into storage shed with the straight back exhaust echoing off the corrugated steel wall was noticeable

Re: Resonator and muffler replacement

Reply #112 – June 08, 2012, 06:55:37 pm

Quote from: Steve – June 08, 2012, 06:47:37 pm

Here are a few pics of the new install. Thanks again to Barry for doing the leg work on how to get this to fit in an 03 w/tag

Welcome to the club. Looks great and awfully familiar

Re: Resonator and muffler replacement

Reply #113 – June 08, 2012, 07:00:51 pm

Steve, Welcome to the world of less heat, more space and added performance. Am wondering of your thoughts once you get it out of the driveway and onto the open road with your window closed, you will not hear any difference inside the coach, but will smile from the response of the go pedal.
Dave M

Re: Resonator and muffler replacement

Reply #114 – June 08, 2012, 07:29:21 pm

Did they pull the body panel or do the "crawl under" dance?

Re: Resonator and muffler replacement

Reply #115 – June 08, 2012, 07:36:35 pm

Quote from: J. D. Stevens – June 08, 2012, 07:29:21 pm

Did they pull the body panel or do the "crawl under" dance?

The panel is hinged at the top in an '03

Re: Resonator and muffler replacement

Reply #116 – June 12, 2012, 12:28:39 am

Just back from the Cody Wyoming Rally and trip thru Yellowstone. We then drove thru Virginia City and Nevada city (old cowboy towns ) and highly recommend that part too. Nice seeing all at the Northwestern pack and finally meeting Barry and Darlene and Harvey and Audrey Nelson.
Now back to my reason for answering this post. Glad you have made the change and I can attest to the difference it has made to our bus. The extra power and cooler running engine has impressed me no end. Enjoy it as I am sure you WILL feel a difference too.
John H

Re: Resonator and muffler replacement

Reply #117 – June 12, 2012, 08:17:04 am

I want to replace my muffler with the aero turbine. Does anyone know how the list Steve has posted may relate to what I will need for my 1999 320?

Re: Resonator and muffler replacement

Reply #118 – June 12, 2012, 11:25:05 am

your set up will most probably be the same as mine but I did not use the Aero, I used a standard 5" resonator. You can see my pictures in this thread a way back around sept (I think)
John H

Re: Resonator and muffler replacement

Reply #119 – June 12, 2012, 11:28:38 am

If your coach is like Steve's, parts list will be very close, if your mechanically inclined, it will be very easy & simple, it not, find a good shop as it will take some cutting to fit, and some creativity to make a nice installation. You did not list your coach length, it might be the same or real close.
Enjoy
Dave M

Re: Resonator and muffler replacement

Reply #120 – June 12, 2012, 05:24:52 pm

I replaced the muffler in my 1996 U320 and believe a 1999 U320 is identical, perhaps others on this forum can confirm.
If they are, I can provide an exact list with part numbers.

I used a Magnaflow muffler rather than an Aero 5050XL because I did not want it to be louder.

I also have 5" stainless flex left over which I would sell.

Re: Resonator and muffler replacement

Reply #121 – June 12, 2012, 06:15:19 pm

Will this parts list for a U320 also work for my 2003 U295?

5050XL
DONALDSON P207365 1 ELBOW 90-5",ALUMINIZED
DONALDSON J190025 1 45 DEG ELBOW
DONALDSON X007785 5 SS SEAL CLAMPS
DONALDSON J000232 1 GUILLOTIN CLMP,DBL SDLE 5"
DONALDSON P224515 1 SS FLEXTUBE FIVE INCH X 15"
DONALDSON P206526 1 PIPE HANGER
DONALDSON P207283 1 STACK STRGHT 5"X18" ALUM 18"

Re: Resonator and muffler replacement

Reply #122 – June 12, 2012, 06:59:14 pm

Tom, my suggestion is to take all the original ex system off and build up what you need by looking at what openings etc you have. I would hate to buy excactly what someone else has only to find they did things a bit different on yours. Are you doing this or are you having a muffler shop do it. I had no trouble here getting all the parts and flex at a local truck repair shop and the one 4-5" coupling I needed I had made at a muffler shop-exacly what I designed_ for $20.
I think you are lucky that your side panel hinges up (Steve's did I believe, where I took all the screws out of mine and took the panel off for ease of access.
John H

Re: Resonator and muffler replacement

Reply #123 – June 12, 2012, 08:12:08 pm

I am another Resonator/Muffler convert having changed over at the end of May!

My first trip with the new setup was to the North Atlantic Rally in Watkins Glen about 600 miles RT and my experience was every bit what I had heard about from everyone here! The throaty sound of the resonator which is heard with the window open actually not loud at all plus sounded great to me, and once the window is closed not much sound if at all.

I definitely felt an increase in power, faster spooling, it held speed up 3% and 4% gradual grades and held speed up 6+% grades better than ever before when towing the Malibu.

As for mileage my last look at the Silverleaf just about 10 miles from home showed 8.3 MPG for entire trip best number I have seen usually more in the 7.7 to 8 MPG range! Will post pictures as soon as taken.

I had mine done locally at McCarthy's Tire, Baltimore for $536 including Tax the muffler AERO5050XL purchased on eBay for $120. The mechanic did not remove the side body panel and the install took approximately 4 Hours. Supplies were flex to connect exhaust from 4" to 5", and a 24" one piece 5" chrome exhaust stack attached to the chrome resonater/muffler which had an angled tip we used as the exhaust exiting the rear. Other supplies used were 1 hanger and 3 clamps. The muffler which was removed weighed about 40 to 50 pounds and had rusted with holes along the seams where the pipe was connected to the muffler. So the change was due regardless.

Tony

Re: Resonator and muffler replacement

Reply #124 – June 12, 2012, 08:44:20 pm

Quote from: Tom Lang – June 12, 2012, 06:15:19 pm

Will this parts list for a U320 also work for my 2003 U295?

Ours was based on Barry's fitment since he has the exact same coach. You'd have to look at the photos of his "tutorial" and see if that looks exactly like your setup.

Exhaust System Replacement - 2003 U320

Note that Steve opted for stainless flex (the only one Donaldson would warranty) and stainless clamps which are more expensive. The straight piece was a sacrificial temporary tail pipe and would not have been needed if we knew what tail pipe would work.

Both Steve and I are impressed with the work Brandon at Inland Truck in Denton did. He is also their Allison transmission guy, is very familiar with RVs, and likes working on Foretravels.

Michelle

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