Built by the team at Lethal Performance, this guide breaks down every major Explorer ST upgrade with the tech behind it, realistic power expectations, and install difficulty. With years of Explorer ST experience and over 20 years in the performance industry, we've put together everything you need to upgrade smarter, avoid wasted money, and unlock the 3.0L EcoBoost's full potential.
Cooling & Induction Systems
The twin-turbo 3.0L lives and dies by airflow and heat management. This is where every Explorer ST build should start: keep the intake clean, the charge air cold, and the boost where it belongs.
Catch Cans
A reservoir in the PCV system that traps oil vapor and blow-by before it reaches your intake. It keeps valves and intercoolers clean, reduces knock, and extends service intervals, which is crucial on a turbocharged direct-injection engine.
UPR Products Catch Can
Billet aluminum with an internal baffle, easy-drain valve, OEM-style push-connect fittings, and a lifetime warranty.
Shop UPR Catch Cans ›J&L Oil Separator
Internal wire-mesh separation, included -8AN fittings, and a larger 3oz capacity for extended service intervals.
Shop J&L Systems ›Cold Air Intakes
A high-flow filter and tubing setup that draws in cooler, denser air. Gains are modest on their own, but a CAI sharpens throttle response and adds sound. The FenFab V2 in particular amplifies turbo noise for a more aggressive feel.
aFe Momentum GT
Pro 5R oiled media, dyno-proven gains, OEM-quality fitment, and an included heat shield.
View aFe Intake ›S&B Cold Air Intake
Cotton cleanable filter, no oiling required, precision-molded tubes, and 99.9% filtration. Great value.
View S&B Intake ›FenFab V2 Intake
Maximum turbo noise, carbon fiber construction, and a show-quality finish for the engine bay.
View FenFab V2 ›Intercoolers
An air-to-air heat exchanger that cools compressed turbo air before it enters the engine. Stock units heat-soak fast. Aftermarket cores drop charge temps by up to 85°F and add over 200% more volume, keeping timing stable and power consistent.
CV Fabrication Intercooler
Bar-and-plate core with 50% more volume, a direct OEM-fit replacement, proven on the dyno. 2025-compatible.
Shop CV Fabrication ›Whipple Intercooler
Massive cooling capacity, maximum-flow design, premium construction, and a lifetime warranty.
Shop Whipple ›Livernois Upgrade Package
High-flow design with increased surface area, OEM-style black coating, and a direct bolt-on fit.
View Intercooler ›Charge Pipes
The tubing that carries compressed air between the turbo, intercooler, and throttle body. Factory plastic pipes flex and crack under boost. Upgraded aluminum pipes prevent leaks, cut pressure loss, and improve turbo response.
CV Fabrication Charge Pipes
Mandrel-bent aluminum with CNC-machined flanges. Eliminates factory restrictions; required for most intercooler upgrades.
Shop CV Fabrication ›FenFabrication Charge Pipes
Lightweight aluminum with improved flow, a show-quality finish, and all hardware included.
Shop FenFabrication ›Blow-Off Valve Systems
Two paths here: a full performance BOV that eliminates boost leaks, or an adapter that adds the sound without touching ECU function.
TurboSmart BOV Complete
Dual-port, professional-grade replacement that eliminates potential boost leaks. Tuning optimization available.
View TurboSmart BOV ›AMP BOV Adapter
Sound enhancement only. Keeps OEM function, needs no ECU changes, fully reversible, multiple colors.
View AMP Adapter ›Exhaust System
Freeing up the turbos is the fastest real power on the platform. Downpipes are the primary gain; a cat-back completes the tone and a turbo-back setup ties it all together.
Downpipes
The piping that connects the turbos to the rest of the exhaust, often housing the cats. Stock downpipes restrict flow and build backpressure. Upgraded stainless, mandrel-bent downpipes improve spool and can add 10 to 30 HP when paired with tuning.
Lethal Performance Competition Downpipes
Our own high-flow competition downpipes for maximum spool and flow.
Shop Lethal Downpipes ›Cat-Back Exhausts
Everything from the cats back: mufflers, resonators, and tailpipes. A cat-back improves flow and sound, and paired with downpipes it completes a turbo-back system for a deeper, more aggressive tone.
Corsa
Premium stainless with Corsa's no-drone technology and a refined-to-aggressive tone.
Shop Corsa ›Thermal R&D
Aggressive tone with quality stainless construction and proven fitment.
Shop Thermal R&D ›Listen: Corsa · Thermal R&D · AWE
Mid-Pipes
The pipes that connect the downpipes to the cat-back. Our 2.5-inch stainless mid-pipes tie the system together for a true turbo-back setup.
Lethal Performance 2.5" Mid-Pipes
2.5-inch stainless steel mid-pipes for 2020-2025 Explorer ST, the link between downpipes and cat-back.
Shop Mid-Pipes ›Suspension & Driveline
The ST is heavy and the chassis flexes under power. Bracing, springs, and the right dampers transform how it drives, and the driveline upgrades keep the power planted.
Differential Braces
The single most important driveline upgrade on the ST. Bracing the rear diff cuts wheel hop and slop under power for cleaner launches and a more connected feel.
DX Suspension Billet Brace
Billet aluminum brace, our top pick for cutting wheel hop.
Shop DX Suspension ›Strut Tower Braces
Tie the strut towers together to reduce front-end flex and sharpen turn-in.
Sway Bars & End Links
Bigger bars and stiffer end links flatten body roll and balance the chassis.
Lowering Springs
Drop the stance and lower the center of gravity while keeping the factory dampers.
Shocks, Struts & Coilovers
For the biggest handling change, upgrade the dampers themselves or go full coilover for ride-height and stiffness adjustability.
Steeda Pro-Action Front Strut
Steeda front strut kit for improved damping and control.
Shop Steeda ›BC Racing BR Coilovers
Fully adjustable BR-series coilovers for ride height and damping.
Shop BC Racing ›Wheel Spacers
An easy way to fill the fenders and improve stance and stability.
Lethal Performance Wheel Spacers
Hub-centric 6061-T6 aluminum spacers with extended studs and multiple thickness options.
Shop Wheel Spacers ›Wheel spacer installation guide
Complete Lethal Performance Packages
Prefer a matched, no-guesswork setup? Our bundled packages pair the right components for a complete transformation while keeping daily drivability.
Handling Package
Carefully matched components for a complete handling transformation, daily-drivable, with warranty coverage.
View Handling Package ›Rear Subframe Package
A complete rear suspension overhaul that eliminates wheel hop and maximizes traction. Track-proven.
View Subframe Package ›Fuel System & Engine Tuning
This is where the real power lives. A tune alone wakes the ST up; add fueling support and the 3.0L will make numbers that embarrass much more expensive machinery.
High-Pressure Fuel Pumps (HPFP)
The pump that feeds the direct-injection system. Stock pumps max out near 500 to 550 whp. An upgraded HPFP supplies the flow needed for higher boost or ethanol blends, keeping air-fuel ratios safe under load.
Fuel Injectors
Precision nozzles that spray fuel into the chamber. Larger injectors prevent starvation on E85 or high-horsepower setups; Stage 3 fueling can support over 700 whp with the right tune.
Tuning Solutions
ECU recalibration is the highest-value upgrade on the platform. Even on stock hardware a tune can add 60 to 100 whp. With bolt-ons and fueling, gains of 150 whp or more are on the table, all while improving drivability. We don't write tunes in-house; we work with the specialists who own this platform.
Fuel System Upgrades
Nostrum Stage 1 Bundle
High-flow injectors plus an upgraded HPFP with install kit and tuner-friendly data. Supports up to 550HP.
Shop Nostrum Bundle ›Nostrum Components
Buy the injectors or the HPFP individually, mix and match to your power target.
Shop HPFP ›Xtreme DI Complete System
Configurable HPFP base with an optional injector upgrade and professional tuning support.
Shop Xtreme DI ›Engine Calibration & Tuning
ZFG Racing
Explorer ST platform specialists. Custom calibration with multiple revisions and real-world testing.
Shop ZFG Tune ›5 Star Tuning
Conservative daily-driver calibrations, proven reliability, multiple octane options, lifetime updates.
Shop 5 Star ›Livernois Motorsports
Complete hardware-and-calibration packages, track-tested, with warranty coverage.
Shop Livernois ›Ford Performance Calibration
Factory-backed, warranty-friendly tune delivered with the ProCal 4 tool.
Shop Ford Performance ›Burger Motorsports JB4
Reversible piggyback tuner with multiple maps, data logging, and user-adjustable parameters.
Shop JB4 ›Complete Performance Stage Packages
Two proven recipes, developed through real-world testing. Figures are estimates and vary with fuel, weather, and tune.
| Package | Key Mods | Est. Output | Best For |
|---|---|---|---|
| Street Stage | Cold air intake, catch can, downpipes, cat-back, intercooler, custom tune | 450-475 HP / 500-525 lb-ft | Daily-drivable, premium fuel, big sound and response |
| Performance Stage | Adds upgraded injectors, HPFP, charge pipe, BOV, differential brace, aggressive tune | 500-550 HP / 575-625 lb-ft | Track-capable, sub-5s 0-60, premium fuel required, pro install |
Ready to Transform Your Explorer ST?
From mild bolt-ons to a complete transformation, our team has the expertise and the components to hit your power goals safely and reliably. Tell us your target and we'll spec the build.
Related reading: 2020-2025 Explorer ST Upgrades · Explorer ST Wheel Spacers · The Custom Tuning Process
