Quiet muffler recommendations

I know this was discussed many times in the past, but a search didn't find anything. My 05 still has the original exhaust and muffler, but the muffler is starting to get a hole rusted in the bottom, and I'm sure it's not going to last a long time here in Pennsylvania.

I like it nice and quiet, but want to replace the exhaust (cat back) with something stainless. Any recommendations? I had a Diamond Eye from Summit Racing on my 03. Stainless and is still good, but it's a little louder than stock. And Summit doesn't carry them anymore.

 

I thought a Banks Monster exhaust would be cool, but it was WAY too loud. Then I tried putting a resonator in front of it, still too loud (drone) so I went with the Donaldson M090544 (51") and love it. No drone towing at all.

Here is a thread on it showing what it looks like.
https://www.turbodieselregister.com...rience-donaldson-m090544.265417/#post-2566257

and another thread
https://www.turbodieselregister.com/threads/new-to-me-06.274264/#post-2720805

 

Since your original muffler lasted 20 years, why not go stainless on the pipe, but replace the muffler with an OEM muffler? I've been impressed with how quiet the OEM is on my '03, and it's still in great shape, other than some farm dents from rocks.

 

It lasted 20 years in Florida where my truck came from. The exhaust on my 03 lasted about five years in Pennsylvania before the seam weld rusted from one end to the other.

 

Why not keep the OEM until it's gone? I still run the OEM pipes under mine.
Most people that change the exhaust want it loud, the other way around the demand is very little.
More quiet then OEM is probably impossible.

Btw: my muffler had a hole drilled at the far end of to let the condensate drain.

 

Oh I’m not changing it immediately, but am researching what to get when I need to. It’s got a hole in the bottom about 3/4” x 2”. I might be able to braze a patch over it.

 

I ran a Flo-Pro 819NM exhaust with a Donaldson M090544 and really liked the sound, and it was very quiet.

 

Nothing's quieter than OEM. I had a high flo muffler for 10K and returned to a stock one. The muffler guy said I'd take a huge hit in performance and mpg. I can't feel the difference and the mpg are the same.

 

That Donaldson is expensive.

 

Just looked for the first time since buying one, and wow.

The best place to buy them was Ryder Fleet Products, but it appears they are no longer in business.

 

Yeah that is where I got mine as well and I don't recall it being THAT expensive. Dang!

 

I went with a Walker/Napa 22936. It crosses over from the Donaldson MO90544. Price is $127. Be advised, it is for a Mack

https://www.napaonline.com/en/p/EXH22936

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I have the 51” Donaldson with 5” in and out, quiet inside, a little raspy Still outside. Much better than the 5” turbo back alone. That had a wicked drone at 70 mph! If I had a cat it would prolly be close to stock. I want to say $90ish shipped from Ryder FS. Sad to here they’re no longer around. It’s a big sucker! As I recall they had a 30ish in version of the same muffler in their catalogue.

 

5" exhausts on the 5.9 are almost always too large and are known to drone. Unless you're making over 700 rwhp a 4" exhaust is a better option for sound and performance, but many people like the look of a 5" TBE.

 

Was on it when I bought it. I agree, I would have gone 4 and kept the converter.

 

The Mopar muffler (52121604AA) is actually more than the Donaldson M090544.

 

On the plus side, the factory one is p-n-p, no welding, cutting or fabricating involved.
With roughly just 100$ apart I'd go with the factory one.

 

That price is not bad. I had a 4" Mack muffler on my 03 for several years. It was a shorty one (12-16") and worked, but was a little louder than I would like today in my older age. I still have it, but the end flanges are rusting off. The muffler is fine and new ends could be welded on.

I'd really like to get a stainless aftermarket system as nothing else holds up long around here. I bought a stainless Diamond Eye turbo back for my 03 in 2014, and it's still good.

 

Well my muffler just broke off at both ends today! I thought it would last until winter. Time to order a new one!

 

Has anyone tried this
Dynomax Ultra Flo Exhaust Systems 19461
Exhaust System, Ultra-Flo, Cat-Back, Stainless Steel, Polished Tips, Dodge, Pickup, 5.9L Diesel, Kit

from Summit Racing?

It has a muffler similar in shape to the original Dodge. I wonder how the drone is?

https://www.summitracing.com/search...st-systems?SortBy=Default&SortOrder=Ascending