Skip to main content ↑ ↓
Topic: "Aero" muffler replacement on a Cat 3208T?? (Read 804 times) previous topic - next topic

"Aero" muffler replacement on a Cat 3208T??

My muffler looks to be original (its a beast of a muffler) as I put her into the barn for her winter nap yesterday I noticed the pipe was hangin low.  After a quick in inspection the strap rusted through and I found a golf ball sized hole in the muffler :( .  After doing my search and reading some of the numerous posts already on replacing the muffler with the Aero resonator I found that most were for newer models or for the Cummins engines.  My old girl has the CAT 3208T in it.  Anyone out there have any input on pros or cons of this replacement on that engine? 

I'll be reading up on all my options as I don't plan on working on it until around Thanksgiving.  Thanks in advance everyone!!
Jeff
Jeff & Carrie
2023 Geneva 31VA
1989 Grand Villa 36' ORED "The Button Pusher" - GONE 🥺

Re: "Aero" muffler replacement on a Cat 3208T??

Reply #1 –
Not sure it makes any difference what engine you have when it comes to replacing the stock restricting muffler with a resonator as long as you use the one that is matched to your engine. They all breathe better with the stock muffler remved.

Roland
1993 U280 4341
2010 Jeep Liberty
The Pied Pipers

Re: "Aero" muffler replacement on a Cat 3208T??

Reply #2 –
 Ditto.
Take it all off and design your own set up with flex stainless, some of old pipes and resonator. I did not use Aero but standard Walker unit and it works great. Do not think the exhaust emissions care whether it is a stainless unit or plain steel as they both do the same thing.
JohnH
Coachless, now use aircraft. 2003 Ford Travelair TC280 class C. Super shape. Just for 1 yr .
1994 Ford E350 ClassC,total renovation inside and out. Now sold.
2000 U295  36' Cummins 350 c/w Banks Stinger, Resonator upgrade,Solar, LED lites.Residential fridge with slide out pantry. Build 5674. Sold
ex 92 GV 022C ored Cummins. Sold
ex 95 GV240 cat 3116. Sold
2017 Mini cooper s & 2016 land Rover LR2 HSE  LUX.
jhaygarth@aol.com    SKP #130098
treat everyone as you would like to be.

Re: "Aero" muffler replacement on a Cat 3208T??

Reply #3 –
I replaced the muffler on my Cummins engine with an Aero muffler.  I believe that Aero makes both a muffler and a resonator, but about the only difference is that the muffler is longer.  I could look through the one I installed.  Slightly more noise at idle, but can't tell any noise difference at cruise speed.  The turbocharger does most of the muffling.  I did not notice any change in power or mileage after the change, but there may be a slight improvement that is too small to detect without a dyno test.  The shiny stainless will discolor as soon as it gets hot.  Less weight, but I had to rework the brackets and piping.
Jerry Whiteaker former owner 96 U270  36' #4831 Austin,TX-Owner Mods LCD TV w/front cabinet rebuild - LCD TV bedroom - Dual Central AC, either can cool coach w 30 amp - Skylights at roof AC openings - Drop ceiling for ducting of AC - Shower skylight white gelcoat/wood/epoxy frame - Air Springs/Shocks replaced - 2014 CRV - 8K Home Solar - Chevy Volt

Re: "Aero" muffler replacement on a Cat 3208T??

Reply #4 –
Thank you guys for your input....I didn't think it would matter what engine either I just didn't see any post from a CAT owner.  I appreciate it!!!
Jeff & Carrie
2023 Geneva 31VA
1989 Grand Villa 36' ORED "The Button Pusher" - GONE 🥺

Re: "Aero" muffler replacement on a Cat 3208T??

Reply #5 –
We are believers in only choosing the Aero resonator. Price is usually under $100 and its engineering design is something we like.

We have a 4" turbo output pipe, but stepped up to 5" Aero, and ended up stepping down to 4" for chrome tip.

Aero 5" comes in two sizes, that both operate the same, but one may be better for a specific insulation space. AT5050 is shorter and wider and the AT5050X: is longer and thinner. Both are resonators. We found that for the shorter was much better to work with and we had lots of space width wise, so a littler larger diameter made no difference.

For 10 years we towed a 2002 4,300 lb Jeep Grand and when we got our new 2012 5,400 lb Jeep Grand, we noticed some power loss from additional weight when driving. But we love our Jeep, so we did not care about the increased weight, which did not cause any overheating etc. Then after we put on the Aero resonator, we noticed we were again towing like the older Jeep, so we feel the change from muffler to resonator noticeably improved our power.

Here is our installation story:
Exhaust System Replacement - 1997 U270

Do it yourself or find a small muffler shop that can weld and you will find the cost to install is not very much. And well worth it.

Re: "Aero" muffler replacement on a Cat 3208T??

Reply #6 –
Barry,

After reading your complete write up I was leaning toward the shorter one.  Just wasn't convinced do to my older engine.  I'm convinced now!!! ^.^d
Jeff & Carrie
2023 Geneva 31VA
1989 Grand Villa 36' ORED "The Button Pusher" - GONE 🥺

Re: "Aero" muffler replacement on a Cat 3208T??

Reply #7 –
In our setup, turbo exit faces toward front of motorhome. We made a 180 to get exhaust facing rear and the shorter Aero gave us more room for the two 5" 90 degree fittings.

We changed to a resonator before our original muffler had visible problems, so we were not sure if the switch was necessary. But if the muffler is damaged, a change is necessary, and switching to resonator is a good choice and probably less expensive.

Re: "Aero" muffler replacement on a Cat 3208T??

Reply #8 –
Somewhere on this forum, I did a writeup with pix on the Aero muffler replacement on our U280 3208t. i bought a 4" to 5" adapter to go from the turbo outlet elbow, used a short section of solid 5" to a 5" mandrel bend to the resonator, and re-used the rest of the stock tailpipe as it is 5" already. A couple mufller brackets, a short bit of quality time with my mig welder, and done. Total cost was under 200 bucks and took a couple-three hours at most. I didn't use flex pipe at all, the stuff wears out and the OEM muffler mount has plenty of movement designed into it. It's a mite louder than stock, but you can only tell that if a window is open. There were small gains in accelleration and maybe fuel economy (we avged 10.9 on our 3500 mile road trip including lots of huge climbs for things like Yellowstone) but I had no really good solid starting numbers for either. But I did see around 100 degrees less exhaust gas temp, which is nothing but a Good Thing and implies a fair bit of backpressure removed. Our neighbors can hear us coming, but they say it doen't seem any louder, just more... semi truck-like. *I* think it sounds fantastic. However in the interest of full disclosure, I am sort of an infant when it comes to the noise a decently breathing V8 makes, diesel, gas, nitro, or otherwise! If you can't find it ( I couldn't after brief search.. hmm. search button not working or did I never post pix? ) and want photos, lemme know and I'll post em here. 
Jay
1989 U280 SE, 36', 3208T Cat, build 3292

Re: "Aero" muffler replacement on a Cat 3208T??

Reply #9 –
Quote from: twobus –
Somewhere on this forum, I did a writeup with pix on the Aero muffler replacement on our U280 3208t.

If you can't find it ( I couldn't after brief search.. hmm. search button not working or did I never post pix? ) and want photos, lemme know and I'll post em here.

I can't find it in your history, either.  Just a mention that you were going to do it here:  What did you do to your coach today III
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: "Aero" muffler replacement on a Cat 3208T??

Reply #10 –
Ah so. Something that "was gonna" happen but getting ready for that road trip made it get lost in the shuffle.
Jay
1989 U280 SE, 36', 3208T Cat, build 3292

Re: "Aero" muffler replacement on a Cat 3208T??

Reply #11 –
Thanks for your input Jay....Greta to hear about the price too !! ^.^d
Jeff & Carrie
2023 Geneva 31VA
1989 Grand Villa 36' ORED "The Button Pusher" - GONE 🥺