Resonator Installation

Here are a few pics of the resonator install, this is what worked on a 2003 with tag axle. Different years will have different pipe diameters coming off the turbo, etc, so do your homework before you buy parts.


The parts I used were all Donaldson exhaust parts, I got them all from Filter Products They had the best pricing I could find, plus they worked with the non commercial user. The site is not much visually, you basically need to know your part numbers and enter them, most things you can just buy one of, some small parts only by the case.

Anyway here is what we used on our coach:

Mfg P/N Qty Description
DONALDSON P207365 1 ELBOW 90-5”,ALUMINIZED
DONALDSON J190025 1 45 DEG ELBOW
DONALDSON X007785 4 SS SEAL CLAMPS
DONALDSON J000232 2 GUILLOTIN CLMP,DBL SDLE 5”
DONALDSON P224515 1 SS FLEXTUBE FIVE INCH X 15” (cut down as needed to make things fit)
DONALDSON P206526 1 PIPE HANGER
DONALDSON P207283 1 STACK STRGHT 5”X18” ALUM 18” (just for alignment and temp tailpipe)

The most expensive item was the SS flex @ 40.75 for 15 inches! … this particular flex is a much heavier gauge stainless material over standard parts store flex and has a 12 month/120,000 mile warranty (onhighway vehicles only). You could save some money here and get regular SS flex or even non SS flex, but I don’t recommended that.

The next most expensive thing was the 5 stainless seal clamps, again you could save some money with non SS or just use Guillotine Clamps (for the non flex joints).

The “resonator” in this case was a Aero Exhaust Resonated Turbine 5050XL Series Performance Muffler. Its 5” in/out, 7.5” overall diameter, 30” long. The tailpipe is currently straight out the back while we wait on the curved tip to arrive, and standing 6 feet behind the coach while its idling the exhaust airflow is quite strong, like a small leaf blower.

  • The noise level is up somewhat from where it was, but nothing that seems offensive, more throaty is the best description.
  • The turbo does spool up faster since there is less back pressure, you will notice more power “off the line” and when pulling up a hill. I’ve noticed the ability to stay in a higher gear when going up inclines.
  • I’ve not noticed any change in MPG, some have reported increases but I’ve not seen anything that I would not account to trip differences (traffic, wind, loading, etc).
  • An additional benefit was that the bedroom area stays much cooler, seems the new exhaust traps less heat.

Update

After the first year with the Aero, we swapped it out for a MagnaFlow. The MaganFlow was about the same size and the swap did not require much work. The reason was the Aero noise level was a bit to much for our taste, especially when under load. It was a bit too loud in campgrounds and when going through small villages as well as neighborhoods. Certainly loud enough to alert zombies when passing graveyards. I’d say the MagnaFlow provides 85% of the same pedal performance, but is not much louder than the old 50G oil drum stock muffler, much more civil than the Aero.