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Thermal R&D Exhaust

2020-2026 Explorer ST - 2.5" Catback Exhaust w/ Black Coated Tips

2020-2026 Explorer ST - 2.5" Catback Exhaust w/ Black Coated Tips

SKU:A/B/C-910-C

Regular price $1,599.99
Regular price Sale price $1,599.99
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Why Thermal R&D?

Drone Free
Lifetime Warranty
Top Quality Construction
4.8 ★ Customer Rated
Manufactured In The USA
Free Shipping To Lower 48 States

⚠️ 2026 Explorer ST owners: Please see the GPF compatibility note below before ordering.

2.5" Front Pipe Back Exhaust - Ford Explorer ST

Some Explorer ST owners want to wake the neighbors. Others just want their 400 horsepower SUV to finally sound like it should. The 2.5" front pipe back exhaust is built for the second group — a deep, refined exhaust note that adds character without overwhelming the cabin.

It uses the same True Helmholtz Technology, the same T304 stainless steel construction, and the same drone-free highway manners found in our larger systems, just dialed back for a smoother daily driving experience.

Key Features

  • Lifetime Manufacturer's Warranty
  • Direct fit to OEM hangers and catalytic converters
  • 2.5" T304 stainless tubing for a deep, controlled exhaust tone
  • True Helmholtz Technology eliminates cabin drone at cruise
  • Dual 4" angle-cut black coated tips with OEM-style fitment

Like every exhaust we build, this system uses mandrel-bent T304 stainless steel for long-term durability, corrosion resistance, and consistent exhaust flow.

The system mounts directly to the OEM catalytic converters and downpipes, uses factory hanger locations, and fits the OEM rear valance with no cutting or welding required.

True Helmholtz Technology uses precision-tuned resonance chambers to target and cancel the low-frequency exhaust tones that cause cabin drone. The result is a system that sounds aggressive under throttle while remaining smooth and comfortable during daily driving and highway cruising.

The dual 4" angle-cut black coated tips are sized specifically for the Explorer ST rear valance, delivering a clean, flush fit with a stealthy blacked-out finish.

Prefer a different look? Also available in polished stainless. Want more volume? Check out the full 3" system.

System Specs

  • 2.5" T304 stainless steel mandrel-bent tubing
  • Dual 4" angle-cut black coated tips
  • True Helmholtz Technology to eliminate cabin drone
  • Direct bolt-on installation using OEM hangers
  • Fits OEM valance with no cutting or welding required
  • Lifetime Manufacturer's Warranty

⚠️ Heads up for 2026 Ford Explorer ST owners: Some 2026 model year Explorer ST vehicles may be equipped with a Gasoline Particulate Filter (GPF) depending on trim level and production market. Installing this exhaust on a GPF-equipped vehicle may trigger a Check Engine Light.

Does my 2026 Explorer ST have a GPF?
The easiest way to check is your VIN or the Vehicle Emissions Control sticker located under the hood. If GPF is listed, this system is not compatible with your vehicle.

Not sure? Contact us before ordering and we'll help you confirm compatibility. We are also actively developing a GPF-compatible Explorer ST system, so stay tuned for updates.

Installation Video

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2020-2026 Explorer ST - 2.5" Catback Exhaust w/ Black Coated Tips has a rating of 4.9 stars based on 58 reviews.

Overall rating: 4.948276 / 5 from 58 reviews.

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Review highlights

Reviews

The ST is Awakened

"Bought the 2. 5 inch system based on internet sound clips and reviews. The sound is perfect - no drone at highway speeds, quiet when cruising, raucous when on it. The Hoover vacuum sound is gone. Fit and finish of the system looks excellent and it fit my ‘25 ST perfectly. Great product at a fair price."

Steven W. (5/5)

Very happy with my purchase

"Very happy with my purchase of this exhaust. The packaging was great, parts fit perfect, and the installation was as straight forward as the video. My ST sounds great, not too loud, just enough to know it’s a performance exhaust."

Brandon B. (5/5)

Quality and sound you can trust

"Recently purchased the 2. 5” w/ black tips for my 2026 Explorer ST. The sound is perfect, and really make the ST a totally different car! Took just over 2 1/2 hrs to install in my driveway. Highly recommend to anyone looking for that exhaust sound!"

Alberto H. (5/5)

The Sound This SUV Should Have Had from the Factory

"The stock exhaust on the Explorer ST is a joke, but the Thermal R&D 2. 5-inch system completely transformed it. I was worried about the V6 sounding 'raspy' or like a clapped-out sedan, but this has a deep, mature rumble. This is the kit if you wanted that signature deep growl without the "trumpet" sound at high RPMs."

Scott A. (5/5)

Thermal 2. 5 exhaust for my 2025 Explorer ST

"The Thermal exhaust is definitely a high-quality exhaust. It came complete and color coordinated for driver and passenger sides. I would highly recommend them as there exhaust kits doesn’t drone while cruising, and isn’t super loud. A+"

James W. (5/5)

Perfect for the Explorer ST

"Lives up to the hype. Easy, straight forward install. Nice growl with zero drone, and not overly aggressive until you stomp on the gas pedal. The cold start is a little louder than expected, which I like (my wife not so much)."

Rick B. (5/5)

Great exhaust!

"I swapped to this exhaust from the AWE 3” exhaust because with aftermarket high flow cat downpipes it started to drone really bad after a year. It was super annoying on road trips and with family. Glad I swapped to the Thermal 2. 5” and wish I would have started out with it."

Lee H. (5/5)

"This thing sounds great and is waaaay better than stock from a sound, aesthetic and functional perspective. The team was great and kept me informed during the build"

Chris (5/5)

2. 5 catback

"Exhaust went on perfectly no issues. Not too loud for the wife. Sounds great!"

john v. (5/5)

Perfect Exhaust

"Love the 2. 5inch paired with Cvf DPs. has just the right tone for daily needs. Cold start and WOT sound amazing. No drone, and highway speeds i notice nothing. Went together nicely, no issues with fitment or alignment. Very Happy."

ryan l. (5/5)

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