Complete 2020-2025 Ford Explorer ST Modifications Guide

Built by the team at Lethal Performance, this guide breaks down every major upgrade with tech explanations, expectations for power, drivability, 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 time, and unlock your SUV’s full potential.

Cooling & Induction Systems
Exhaust System Engineering
Suspension & Driveline
Fuel System & Tuning

Cooling & Induction Systems

Catch Cans

What this is: A reservoir in the PCV system that traps oil vapor and blow-by before it reaches your intake.

Why it matters: Keeps valves and intercoolers clean, reduces knock, and extends service intervals—crucial for turbocharged direct-injection engines.

Cold Air Intakes

What this is: A high-flow filter and tubing setup designed to draw in cooler, denser air.

Why it matters: Gains are modest solo, but CAIs sharpen throttle response and add sound. The FenFab V2 in particular amplifies turbo noise for a more aggressive driving experience.

Intercoolers

What this is: An air-to-air heat exchanger that cools compressed turbo air before it enters the engine.

Why it matters: Stock units heat-soak fast. Aftermarket cores like CV Fabrication’s drop charge temps by up to 85°F and add 214% more volume, keeping timing stable and power consistent.

Charge Pipes

What this is: Tubing that carries compressed air between the turbo, intercooler, and throttle body.

Why it matters: Factory plastic pipes flex or crack under boost. Upgraded aluminum pipes prevent leaks, reduce pressure loss, and improve turbo response.

Oil Catch Can System - Preventive Maintenance

UPR
Easy Installation
The Explorer ST's 3.0L EcoBoost utilizes a closed crankcase ventilation system that recirculates oil-laden vapor from the crankcase back through the intake tract. In direct injection engines, this creates carbon buildup on intake valves since fuel injection doesn't provide the cleaning action present in port injection systems. The catch can system intercepts these vapors before they reach the intake manifold.

UPR Products Catch Can

  • Billet aluminum construction
  • Internal baffle system
  • Easy-drain valve
  • OEM-style push-connect fittings
  • Lifetime warranty
Shop UPR Catch Cans Tech Video

J&L Oil Separator

  • Internal wire mesh separation
  • -8AN fittings included
  • Larger 3oz capacity
  • Extended service intervals
  • CNC machined aluminum
Shop J&L Systems

Cold Air Intake Systems

FenFab V2 intake on Explorer ST
Easy Installation

Performance Gains with Professional Tune

+15 Peak HP
+20 Peak Torque
15% Better Response
While the factory airbox provides adequate flow for stock applications, aftermarket intake systems reduce restriction at higher RPM ranges and provide enhanced acoustic feedback from the turbochargers. The most significant gains occur when combined with tuning that takes advantage of the improved airflow characteristics.

aFe Momentum GT

  • Pro 5R oiled filter media
  • Dyno-proven gains
  • OEM-quality fitment
  • Heat shield included
  • 90-day money-back guarantee
View aFe Intake Installation Video

S&B Cold Air Intake

  • Cotton cleanable filter
  • Excellent value proposition
  • Precision-molded tubes
  • No oiling required
  • 99.9% filtration efficiency
View S&B Intake

FenFab V2 Intake

  • Maximum turbo noise output
  • Aggressive styling
  • Carbon fiber construction
  • Show-quality finish
  • Enhanced engine bay aesthetics
View FenFab V2
This intake produces the most aggressive turbo sound of any option available.

Intercooler Systems

CVF intercooler front mount on Explorer ST
Moderate Installation

Thermal Management Performance

50-80°F IAT Reduction
+25 HP with Tune
100% Consistency
The factory intercooler becomes the primary thermal bottleneck once boost pressure increases beyond stock levels. Heat soak reduces knock resistance, forcing the ECU to retard timing and reduce boost pressure. Upgraded intercoolers maintain consistent charge air temperatures even under sustained load conditions.
2025 Model Compatibility: Only CV Fabrication currently offers direct-fit intercoolers for 2025 Explorer ST. Other manufacturers require aftermarket charge pipes for proper fitment.

CV Fabrication Intercooler

  • 2025 model year compatible
  • Direct OEM replacement
  • Bar-and-plate construction
  • Proven dyno results
  • 50% larger core volume
Shop CV Fabrication

Whipple Intercooler

  • Massive cooling capacity
  • Track-proven performance
  • Premium construction
  • Maximum flow design
  • Lifetime warranty
Shop Whipple
Requires aftermarket charge pipes on 2025 models.

Livernois Intercooler Upgrade Package

  • High Flow design for reduced pressure drop
  • Increased surface area for improved thermal exchange
  • OEM-Style black coating to provide stealth improvement
  • Direct bolt on design to allow for easy installation
  • Reduced intake temperature
View Intercooler

Charge Pipe Systems

CVF intercooler front mount on Explorer ST
Moderate Installation
Charge pipes connect the intercooler outlets to the intake manifold and throttle body. Aftermarket charge pipes eliminate the accordion-style flexible sections that can collapse under high boost pressure, while also providing improved routing for intercooler upgrades.

CV Fabrication Charge Pipes

  • Mandrel-bent aluminum construction
  • Eliminates factory restrictions
  • Required for most intercooler upgrades
  • CNC-machined flanges
  • Professional powder coating
Shop CV Fabrication

FenFabrication Charge Pipes

  • Lightweight aluminum design
  • Improved flow characteristics
  • Show-quality finish
  • All necessary hardware included
  • Lifetime craftsmanship warranty
Shop FenFabrication

Blow-Off Valve Systems

CVF intercooler front mount on Explorer ST
Easy Installation
The Explorer ST uses electronic blow-off valves that the ECU monitors for proper operation. Two upgrade paths exist: complete BOV replacement for performance benefits, or adapter-only solutions for enhanced sound without ECU complications.

TurboSmart BOV Complete

  • Complete performance replacement
  • Dual-port design
  • Eliminates potential boost leaks
  • Professional-grade construction
  • Tuning optimization available
View TurboSmart BOV Tech Video

AMP BOV Adapter

  • Sound enhancement only
  • Maintains OEM functionality
  • No ECU modifications needed
  • Reversible installation
  • Multiple color options
View AMP Adapter Installation Video

Exhaust System

Cat-Back Exhausts

What this is: Exhaust components from just after the catalytic converters to the tailpipes, including mufflers and resonators.

Why it matters: A cat-back system improves flow and sound. When paired with downpipes, it completes a turbo-back system, optimizing power while giving the Explorer ST a deeper, more aggressive tone.

Mid-Pipes

What this is: The pipes that connect the downpipes to the cat-back system.

Why it matters: Upgraded mid-pipes reduce bottlenecks in the exhaust path and allow a true free-flowing turbo-back setup. This maximizes the gains from both downpipes and cat-backs.

Downpipe Systems - Primary Performance Modification

CVF intercooler front mount on Explorer ST
Moderate Installation

Downpipe Performance Impact

+40 Peak HP
+60 Peak Torque
3-5 PSI More Boost
Factory downpipes represent the most significant restriction in the Explorer ST's exhaust system. The OEM configuration uses small-diameter tubing with multiple catalytic converters that create substantial backpressure. Aftermarket downpipes typically increase diameter from 2.25" to 3.0" while reducing catalyst count, dramatically improving exhaust flow.
These products are designed for off-road use only. Installation will trigger diagnostic trouble codes requiring professional tuning. Some states have strict emissions regulations regarding catalyst removal.

Lethal Performance by Kooks

  • Lethal Performance signature product
  • 3.0" stainless steel construction
  • Flex joints for thermal expansion
  • Complete gasket and hardware kit
  • Dyno-developed and tested
Shop Lethal Downpipes

CV Fabrication Downpipes

  • CNC mandrel-bent construction
  • Precision-welded O2 bungs
  • Excellent fitment tolerance
  • Professional powder coating
  • Track-tested durability
Shop CV Fabrication

SPD Downpipes

  • Budget-friendly option
  • Performance without compromise
  • Great entry-level choice
  • Stainless steel construction
  • Proven reliability record
Shop SPD

FenFabrication Downpipes

  • Precision manufacturing
  • Optimal flow design
  • Show-quality finish
  • All mounting hardware
  • Performance guarantee
Shop FenFabrication

Cat-Back Exhaust Systems

CVF intercooler front mount on Explorer ST
Easy Installation
Cat-back systems replace the exhaust from the catalytic converters to the rear exit points. While performance gains are modest compared to downpipes, cat-back systems significantly improve exhaust note while reducing backpressure. Quality systems eliminate drone through careful acoustic engineering.

Corsa Performance (Lethal Exclusive)

  • Lethal Performance exclusive
  • Patented RSC drone elimination
  • Premium acoustic engineering
  • Lifetime warranty coverage
  • Track-tested performance
Shop Corsa Listen to it

Thermal R&D Systems

  • Multiple tip configurations
  • Available valved systems
  • Quiet/loud mode switching
  • Stainless steel construction
  • Professional installation available
Shop Thermal R&D Listen to it

AWE Track Edition

  • Aggressive sound profile
  • Diamond black tips included
  • Excellent build quality
  • Track-focused design
  • Performance-oriented tuning
Shop AWE Listen to it
For maximum performance benefits, combine any cat-back system with our Lethal Performance mid-pipes to create a complete turbo-back exhaust configuration.

Lethal Performance Mid-Pipes

  • Replaces restrictive factory section
  • 2.5" stainless steel construction
  • Creates complete turbo-back system
  • Optimized flow characteristics
  • Compatible with all cat-backs
Shop Mid-Pipes Listen to a Turbo-back setup

Suspension & Driveline Engineering

Differential Braces

What this is: Reinforcements that secure the rear differential housing to prevent flex or bolt failures under load.

Why it matters: The Explorer ST’s stock single-bolt diff mount is a weak point. A brace prevents movement and breakage under hard launches or high torque, improving drivetrain stability.

Strut Tower Braces

What this is: A rigid bar that ties the tops of the front strut towers together.

Why it matters: Reduces chassis flex during cornering, sharpening steering response and increasing front-end stability for more predictable handling.

Sway Bars & End Links

What this is: Sway bars reduce body roll, and end links connect them to the suspension.

Why it matters: Upgraded sway bars and end links minimize lean in corners, keeping the Explorer ST flatter and more composed during aggressive driving.

Lowering Springs

What this is: Performance springs that reduce ride height and stiffen suspension response.

Why it matters: Lowering the Explorer ST’s center of gravity improves balance and turn-in while giving the SUV a more aggressive stance without sacrificing comfort.

Shocks, Struts & Coilovers

What this is: Damping components that control suspension movement. Coilovers integrate adjustable springs and shocks in one unit.

Why it matters: Stock dampers are tuned for comfort, not control. Performance struts or coilovers tighten ride quality, improve weight transfer, and give tunable handling characteristics.

Wheel Spacers

What this is: Machined discs that sit between the hub and wheel, pushing wheels outward for a wider stance.

Why it matters: Improve cornering stability and aesthetics by widening track width. They also help fitment with aftermarket wheels and brakes.

Differential Brace Systems - Critical Driveline Support

CVF intercooler front mount on Explorer ST
Moderate Installation
The Explorer ST's factory differential mount uses a single-bolt design that allows excessive differential movement under load. This movement reduces traction effectiveness and can lead to mount failure. Aftermarket braces provide proper triangulation to eliminate unwanted differential movement while maintaining NVH characteristics.
Differential brace installation should be paired with JXB differential bushing inserts for maximum effectiveness and durability.

DX Suspension Billet Brace

  • Lethal Performance house brand
  • CNC billet aluminum construction
  • Complete triangulation design
  • Eliminates wheel hop
  • Maintains factory NVH levels
Shop DX Suspension Tech Video

Steeda Differential Brace

  • Proven Ford performance heritage
  • Track-tested durability
  • Professional powder coating
  • Complete hardware kit
  • Lifetime warranty
Shop Steeda

AWR Racing Mount

  • Budget-friendly option
  • Single-side reinforcement
  • Prevents bolt failure
  • Easy installation
  • Basic protection upgrade
Shop AWR Racing
Single-bolt design provides protection but doesn't eliminate differential twist like full braces.

Livernois Differential Brace

  • Engineered for performance
  • Precision manufacturing
  • Track-proven design
  • Professional installation available
  • Comprehensive warranty
Shop Livernois

JXB Differential Bushing Insert

  • Complements any differential brace
  • Reduces bushing deflection
  • Maintains factory mounting points
  • Easy installation process
  • Cost-effective upgrade
Shop JXB Insert

Strut Tower Brace Systems

CVF intercooler front mount on Explorer ST
Easy Installation
Strut tower braces reduce chassis flex under cornering loads by connecting the suspension mounting points across the engine bay. This improves steering precision and suspension geometry consistency during dynamic maneuvers.

DX Suspension Strut Brace

  • Lethal Performance exclusive
  • Aluminum tube construction
  • Professional powder coating
  • Precision CNC end plates
  • Enhanced steering feel
Shop DX Suspension

Steeda Strut Tower Brace

  • Ford performance heritage
  • Track-tested effectiveness
  • Show-quality finish
  • Comprehensive mounting hardware
  • Lifetime craftsmanship warranty
Shop Steeda

Sway Bar & End Link Systems

CVF intercooler front mount on Explorer ST
Moderate Installation
Anti-roll bars (sway bars) control body roll during cornering by connecting left and right suspension components. Larger diameter bars reduce body roll but can affect ride quality. Adjustable end links allow fine-tuning of bar preload and suspension geometry.

DX Suspension Sway Bar Set

  • Front and rear bar package
  • Hollow steel construction
  • Multiple adjustment points
  • Professional powder coating
  • Complete bushing kit included
Shop DX Sway Bars

Steeda Sway Bar System

  • Track-proven performance
  • Multiple diameter options
  • Polyurethane bushings
  • Adjustable settings
  • Race-bred technology
Shop Steeda

DX Suspension End Links

  • Adjustable length design
  • Spherical rod end bearings
  • Eliminates binding
  • Professional construction
  • Lifetime warranty coverage
Shop DX End Links

Steeda End Link Kit

  • Heavy-duty construction
  • Spherical bearing design
  • Reduced NVH transmission
  • Track-tested durability
  • Complete hardware package
Shop Steeda

Lowering Spring Systems

CVF intercooler front mount on Explorer ST
Moderate Installation
Lowering springs reduce vehicle height while maintaining proper suspension travel and geometry. Quality springs lower the center of gravity for improved handling while preserving ride quality through careful spring rate selection and progressive design.

DX Suspension Lowering Springs

  • Lethal Performance house brand
  • 1.5" front / 1.2" rear drop
  • Progressive spring rate design
  • Maintains factory ride quality
  • Powder-coated finish
Shop DX Suspension

H&R Sport Springs

  • German engineering heritage
  • Precision manufacturing
  • TUV certification
  • Lifetime warranty
  • OEM supplier quality
Shop H&R

Eibach Pro-Kit Springs

  • World-renowned suspension brand
  • Cold-wound spring steel
  • Progressive rate design
  • Comprehensive application testing
  • Million-mile warranty
Shop Eibach

Shock, Strut & Coilover Systems

CVF intercooler front mount on Explorer ST
Advanced Installation
Upgrading dampers provides superior control over suspension movement, improving both handling precision and ride quality. Coilovers offer the ultimate adjustability with height, damping, and sometimes spring rate adjustments available.

Kelltrac Performance Shocks

  • Direct OEM replacement
  • Enhanced damping control
  • Maintains factory height
  • Improved handling dynamics
  • Professional installation recommended
Shop Kelltrac

Steeda Pro-Action Struts

  • Track-developed valving
  • Superior build quality
  • Monotube construction
  • Reduced fade characteristics
  • Race-proven technology
Shop Steeda

BC Racing BR Series Coilovers

  • Complete adjustability package
  • 30-way damping adjustment
  • Height adjustment capability
  • Track and street capable
  • Professional setup recommended
Shop BC Racing

Wheel Spacer Systems

CVF intercooler front mount on Explorer ST
Easy Installation
Wheel spacers improve wheel fitment and stance while providing clearance for larger brake components. Quality spacers are hub-centric for proper centering and use extended wheel studs for safety. Proper selection prevents suspension interference.

Lethal Performance Wheel Spacers

  • Hub-centric design
  • Extended wheel studs included
  • Multiple thickness options
  • 6061-T6 aluminum construction
  • Professional installation guide
Shop Wheel Spacers Installation Guide

Complete Lethal Performance Suspension Packages

Suspension Package installed on Explorer ST
Professional Installation
Our engineering team has developed complete suspension packages that deliver optimal performance while maintaining daily drivability. These packages include components specifically selected for compatibility and performance synergy.

Lethal Performance Handling Package

  • Complete handling transformation
  • Carefully matched components
  • Maintains daily drivability
  • Professional installation included
  • Comprehensive warranty coverage
View Handling Package

Rear Subframe Upgrade Package

  • Complete rear suspension overhaul
  • Eliminates wheel hop completely
  • Maximum traction optimization
  • Professional installation required
  • Track-proven effectiveness
View Subframe Package

Fuel System & Engine Tuning

High-Pressure Fuel Pumps (HPFP)

What this is: A pump that delivers pressurized fuel to the direct injection system.

Why it matters: Stock pumps max out near 500–550 whp. Upgraded HPFPs provide the extra flow needed for higher boost or ethanol blends, ensuring safe air-fuel ratios under load.

Fuel Injectors

What this is: Precision nozzles that spray fuel into the combustion chamber at high pressure.

Why it matters: Larger injectors prevent starvation when running E85 or high horsepower setups. Stage 3 upgrades can support over 700 whp with the right tune.

Tuning Solutions

What this is: ECU recalibrations (via handheld tuners or remote tunes) that optimize timing, boost, fueling, and transmission behavior.

Why it matters: Even with stock hardware, a tune can add 60–100 whp. With bolt-ons and fueling upgrades, gains of 150 whp or more are possible, all while improving drivability and safety.

Fuel System Upgrades

CVF intercooler front mount on Explorer ST
Moderate Installation
The Explorer ST's fuel system becomes the limiting factor once power levels exceed approximately 475-500 HP. Both fuel injectors and the high-pressure fuel pump require upgrading to support higher power targets while maintaining proper air-fuel ratios under all operating conditions.

Fuel System Upgrade Requirements

475+ HP Injector Limit
500+ HP HPFP Limit
550+ HP Combined

Nostrum Stage 1 Bundle

  • High-flow fuel injectors
  • Upgraded high-pressure pump
  • Complete installation kit
  • Supports up to 550HP
  • Tuner-friendly calibration data
Shop Nostrum Bundle

Nostrum Individual Components

  • High-flow fuel injectors only
  • High-pressure fuel pump only
  • Mix and match capability
  • Professional installation data
  • Individual component warranties
Shop Injectors Shop HPFP

Xtreme DI Complete System

  • High-pressure fuel pump base
  • Optional injector upgrade
  • Configurable system approach
  • Professional tuning support
  • Comprehensive installation guide
Configure System

Engine Calibration & Tuning

CVF intercooler front mount on Explorer ST
Professional Service

Professional Tuning Results

450+ Stage 1 HP
500+ Stage 1 Torque
550+ Stage 2 HP
Professional calibration optimizes ignition timing, fuel delivery, boost pressure, and transmission parameters for maximum performance while maintaining reliability. Quality tuning accounts for fuel quality, ambient conditions, and specific hardware modifications.
All performance tuning requires premium fuel (91+ octane) and regular maintenance intervals. Custom tuning may void factory warranties and should only be performed by experienced professionals.

ZFG Racing Custom Calibration

  • Explorer ST platform specialists
  • Custom calibration development
  • Multiple revision rounds included
  • Real-world testing protocol
  • Comprehensive support package
Schedule ZFG Tune

5 Star Tuning Services

  • Conservative daily driver approach
  • Proven reliability record
  • Excellent customer support
  • Multiple fuel octane options
  • Lifetime calibration updates
Schedule 5 Star

Livernois Motorsports

  • Complete performance packages
  • Hardware and calibration bundles
  • Track-tested development
  • Professional installation available
  • Comprehensive warranty coverage
Schedule Livernois

Ford Performance Calibration

  • Factory-backed performance tune
  • Warranty-friendly approach
  • ProCal 4 delivery tool included
  • Conservative power gains
  • OEM quality and support
Shop Ford Performance

Burger Motorsports JB4

  • Piggyback tuning system
  • Reversible installation
  • Multiple performance maps
  • Data logging capability
  • User-adjustable parameters
Shop JB4

Complete Performance Stage Packages

Mild Build: Daily Driver Performance (450-475 HP)
Optimal balance of performance and drivability for daily use with weekend enthusiasm. Maintains reliability while delivering substantial power gains across the entire RPM range.
Essential Modifications
  • Cold Air Intake System
  • Oil Catch Can Installation
  • Performance Downpipes
  • Cat-Back Exhaust System
  • Intercooler Upgrade
  • Professional Custom Tune
Performance Targets
  • 450-475 HP Peak Output
  • 500-525 LB-FT Torque
  • Improved Throttle Response
  • Enhanced Sound Character
  • Maintained Daily Drivability
  • Premium Fuel Recommended
Wild Build: Serious Performance (500-550 HP)
Maximum streetable performance for enthusiasts who demand the ultimate in power delivery. Requires premium fuel and regular maintenance but delivers supercar-level acceleration.
Mild Mods Plus:
  • Upgraded Fuel Injectors
  • High-Pressure Fuel Pump
  • Charge Pipe System
  • BOV Upgrade
  • Differential Brace
  • Aggressive Custom Tune
Performance Targets
  • 500-550 HP Peak Output
  • 575-625 LB-FT Torque
  • Sub-5 Second 0-60 Times
  • Track-Capable Performance
  • Premium Fuel Required
  • Professional Installation Essential
Black Friday Deals

There's no better time to mod your Explorer ST than right now. Shop our Black Friday deals at Lethal Performance and get the parts your car deserves today.

Shop Explorer ST Black Friday Deals

Ready to Transform Your Explorer ST?

Our team has developed these recommendations through extensive real-world testing and customer feedback. From mild performance enhancements to complete transformation builds, we provide the expertise and components to achieve your performance goals safely and reliably.

Shop All Explorer ST Parts Contact Us

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