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The twin-turbo 3.0L EcoBoost in the Explorer ST makes good power and almost no noise. Ford went out of its way to keep it quiet, which sells family SUVs and does nothing for the person who bought the ST version on purpose.
This guide covers the systems we have installed, tested, and recorded, plus a couple of other popular options for the platform. The sound clips matter more than the spec sheets here. Exhaust is the one modification you live with every single drive, and tone is entirely personal.
Thermal R&D 3" Cat-Back
A full 3 inch system from the front pipes all the way back, which is a genuine step up from the 2.5 inch systems most of the market offers for this platform. More flow, and a deeper and throatier tone to go with it.
The part that makes it livable is true Helmholtz resonator technology, which cancels drone at cruising speed. That is the difference between an exhaust you enjoy and one you regret on a four-hour highway drive. The front pipes connect after the catalytic converters, so nothing about your emissions equipment changes.
Construction is T-304 stainless with mandrel bent tubing, mounted to the OEM catalytic converters using OEM hangers, and it fits the factory valance. Finished with black coated 4 inch dual angle cut tips.
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AWE Touring Edition Cat-Back
Dual 3 inch with AWE's patented drone-canceling 180 Technology and a precision x-pipe. The x-pipe is what gives it that cleaner, more exotic note rather than the raspy edge EcoBoost sixes can develop.
Slip-fit inlet adapters mate to the factory downpipes properly while leaving an open 3 inch connection, so it does not become the restriction later if you add downpipes. Handcrafted from CNC mandrel bent, US-sourced .065 inch wall T304L stainless, with quad 4.5 inch double-walled slash-cut tips in chrome silver or diamond black.
AWE publishes dyno-proven gains of 13 horsepower and 12 lb-ft at the wheels, and backs the system with their Perfect Fitment Guarantee, No CEL Guarantee, and a lifetime warranty.
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The Full Turbo-Back Setup
This is what the platform can really do. SPD 3 inch 304 stainless catted downpipes, Lethal Performance 2.5 inch stainless mid-pipes, and a cat-back on the end of it. Flow improves from the turbo outlets all the way to the tips instead of just behind the cats.
The difference is not only volume. Freeing up the downpipes is where the actual performance lives on a turbocharged engine, because it lets the turbos breathe out. Throttle response sharpens, flow capacity goes up, and the tone gets meaningfully more aggressive across the whole rev range.
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High RPM Pull
Borla S-Type Cat-Back
The S-Type is the sensible aggressive option. Deep and purposeful, but refined rather than shouty, with polished stainless tips.
Built from premium stainless with a front muffler and an internal H-pipe, it improves power and torque and adds a motorsport character without wrecking daily drivability. If you want people to notice the Explorer without your passengers commenting on it, this is the one.
MRT 2.5" Extreme Cat-Back
MRT's loudest Explorer ST system, and they are not shy about saying so. Handcrafted 2.5 inch T304 stainless with a straight-through design, an H-pipe, and 4 inch angle cut quad tips.
Straight-through means maximum flow and maximum sound, with a deep tone and a strong wide-open-throttle presence. Drone is manageable rather than absent, which is the trade you accept for this much volume. If you want the ST to sound angry, start here.
Which One Should You Buy
Most of these land in a similar performance-oriented range: deeper, more aggressive, better flowing than stock. The differences are in character, and that is what the clips are for.
- Deepest tone with drone under control: Thermal R&D, and the only full 3 inch cat-back here
- Cleanest and most refined note: AWE Touring Edition
- Aggressive but civilized: Borla S-Type
- Loudest: MRT Extreme
- Most actual performance: catted downpipes plus mid-pipes plus any cat-back above
Frequently Asked Questions
What is the best exhaust for a 2020-2026 Explorer ST?
It depends on the tone you want. Thermal R&D gives the deepest note with drone control and is the only full 3 inch system here. AWE Touring is the most refined. MRT Extreme is the loudest. Borla S-Type sits in between.
Do Explorer ST cat-back systems add horsepower?
Modestly. Most improve flow over stock and pick up small gains, with AWE publishing 13 horsepower and 12 lb-ft at the wheels for the Touring Edition. The bigger gains come from upgraded downpipes and a supporting tune.
What is the difference between axle-back and cat-back on the Explorer ST?
Axle-back replaces only the rear section, so it is simpler to install and mostly changes sound. Cat-back replaces everything from the catalytic converters back, which increases flow, deepens the tone, and leaves more room for future upgrades.
Should I run 2.5 inch or 3 inch piping on the 3.0L EcoBoost?
2.5 inch is a good balance for a daily driven or mildly modified ST. A full 3 inch system maximizes flow and makes more sense on a tuned truck or one with upgraded turbos and downpipes.
Will a cat-back improve throttle response?
Yes, somewhat. Reducing restriction helps the twin-turbo 3.0L spool more efficiently, which shows up as sharper throttle response. Downpipes make a bigger difference here than the cat-back does.
Do I need a tune with an exhaust on the Explorer ST?
Not for a cat-back alone. Once you add catted downpipes, a calibration from a reputable tuner is worth doing to get the most out of the setup and keep everything running clean.
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Give the ST a Voice
Pick the tone you want and we will get you the right system. Not sure? Call us, we have heard all of these in person.
