Upgrading the exhaust on your Ford Explorer ST or Lincoln Aviator with the 3.0L EcoBoost engine can transform both the sound and performance of your SUV. We reviewed the top cat-back exhaust systems from Borla, MagnaFlow, MBRP, AWE, Stainless Works, Flowmaster, and aFe Power to help you find the perfect upgrade for aggressive tone, real horsepower gains, and lasting durability.
TOP8 Sounding Exhaust for Ford Explorer ST 2020-2026
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Expert’s Choice
Borla ATAK
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Borla S-Type
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MagnaFlow
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MBRP
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AWE
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Stainless Works
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Flowmaster FlowFX
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aFe Power MACH Force-Xp
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Borla ATAK – Best Overall Sound Exhaust for Ford Explorer
If you want the most aggressive, attention-grabbing exhaust note available for your Explorer ST or Aviator, the Borla ATAK Cat-Back System is the benchmark. This 2.25-inch true dual design uses an internal H-Pipe in the front muffler to boost both performance and tone, while Borla’s engineering keeps unwanted drone completely out of the cabin. The quad 4-inch bright chrome tips give a striking visual upgrade, and buyers can also choose black chrome or carbon fiber finishes to match their style. Built from premium T-304 stainless steel with ultra-smooth mandrel bends, the system bolts directly onto the factory setup without any cutting or modification, making installation straightforward for most DIYers. Precision CNC manufacturing guarantees consistent, accurate fitment every time. Note that this system is not compatible with vehicles equipped with a Gas Particulate Filter (GPF), so double-check your trim before ordering. Backed by Borla’s legendary Million-Mile Warranty, this is an exhaust built to perform and last for the life of your SUV.
- Aggressive sound with zero cabin drone
- True dual design with internal H-Pipe
- Million-Mile Warranty coverage
- Precision CNC fitment, bolt-on install
- Multiple tip finish options available
- Not compatible with GPF-equipped vehicles
- Loud tone may not suit everyone
Expert Recommendation
Choose the Borla ATAK if you want the boldest, most aggressive exhaust note on this list without sacrificing daily drivability, backed by an unmatched warranty.
Borla S-Type – Best Balanced Sound Exhaust for Ford Explorer
For Explorer ST and Aviator owners who want a sportier tone without the ATAK’s raw intensity, the Borla S-Type Cat-Back System delivers a refined, balanced exhaust note perfect for everyday driving. This 2.25-inch true dual system is engineered specifically for the 3.0L V6 EcoBoost engine, pairing performance gains with a smooth, drone-free soundtrack that stays enjoyable on long highway stretches. The system finishes with quad 4-inch black chrome tips on T-304 stainless steel, giving your Explorer a subtle but purposeful appearance upgrade. Borla notes that its Stainless Steel Polish is not recommended on these black chrome tips — a simple wipe with hot water and a microfiber cloth keeps them looking sharp. Like its ATAK sibling, the S-Type uses ultra-smooth mandrel bends and CNC precision manufacturing for accurate, stress-free bolt-on installation. It’s excluded from vehicles with a Gas Particulate Filter, so fitment confirmation is essential. With Borla’s Million-Mile Warranty backing every system, this is a dependable, everyday-friendly upgrade for drivers who want tone without theatrics.
- Balanced, sporty tone without drone
- Great for daily driving comfort
- Million-Mile Warranty included
- Precision-fit bolt-on installation
- Durable T-304 stainless construction
- Not compatible with GPF-equipped vehicles
- Less aggressive than ATAK version
Expert Recommendation
Pick the Borla S-Type if you want a refined, everyday-friendly exhaust tone with the same build quality and warranty as the more aggressive ATAK.
MagnaFlow – Best Value Exhaust for Ford Explorer
The MagnaFlow Street Series Cat-Back System #19515 brings the brand’s signature deep, smooth exhaust tone to the Ford Explorer and Lincoln Aviator while keeping interior noise levels mild for comfortable daily use. The 2.5-inch diameter system features three straight-through mufflers and a quad split rear layout, delivering dyno-proven performance improvements without compromising the SUV’s everyday practicality. Mandrel bent tubing and CNC precision robotic manufacturing ensure the kit fits perfectly right out of the box, and the 100% stainless steel construction resists corrosion for the long haul. Each of the four exhaust tips measures 4 inches in diameter and comes finished in black chrome, giving your Explorer a subtle but aggressive visual statement. Designed with weight and function in mind, this system swaps in easily using existing hardware for a genuine bolt-on installation experience. Proudly manufactured in the USA and backed by MagnaFlow’s limited lifetime warranty, the Street Series strikes an excellent balance between price, sound quality, and long-term reliability, making it a smart pick for shoppers who want proven performance without paying premium pricing.
- Signature deep, smooth MagnaFlow tone
- Mild interior noise for daily comfort
- Corrosion-resistant 100% stainless construction
- Easy bolt-on installation
- Limited lifetime warranty, made in USA
- Sound is milder than ATAK or AWE
- Quad tip design limits customization
Expert Recommendation
The MagnaFlow Street Series is the smart pick for drivers who want proven MagnaFlow sound and dyno-tested gains at a fair, accessible price point.
MBRP – Best Budget Exhaust for Ford Explorer
The MBRP Armor Pro Cat-Back Exhaust delivers serious style and performance at a price point that won’t break the bank, making it a standout budget option for Explorer ST, Platinum, King Ranch, and Aviator owners. Built from 2.5-inch T304 stainless steel tubing, this street profile system exits through a dual rear configuration finished with eye-catching quad carbon fiber tips. Beyond the aggressive look, the system is engineered to deliver improved torque and horsepower, lower exhaust gas temperatures, and sharper throttle response compared to the restrictive factory setup. MBRP’s Armor Pro line is known for durable, no-nonsense construction that handles daily driving and spirited runs alike without issue. Installation follows a straightforward cat-back replacement process, and the system is backed by MBRP’s lifetime warranty for long-term confidence. For shoppers who want a noticeable performance and sound upgrade along with a premium carbon fiber tip appearance, without spending premium-brand money, the MBRP Armor Pro offers outstanding bang for the buck and remains one of the more affordable full cat-back systems on this list.
- Affordable full cat-back system
- Stylish quad carbon fiber tips
- Improved torque, horsepower, throttle response
- Durable T304 stainless steel build
- Lifetime warranty included
- Sound profile less refined than premium brands
- Limited tip finish options
Expert Recommendation
Go with the MBRP Armor Pro if you want a stylish, capable cat-back upgrade with carbon fiber tips at the most budget-friendly price on this list.
AWE – Best Premium Exhaust for Ford Explorer
AWE’s Touring Edition Exhaust Suite represents the pinnacle of EcoBoost exhaust engineering, and it earns its place as the premium pick on this list. The dual 3-inch system runs true 3-inch piping from front to back, complete with slip-fit adapters for factory downpipe compatibility while leaving room for aftermarket upgrades. At its core sits a symmetric X-pipe with tailored geometry that produces a smooth, rasp-free, exotic soundtrack out of the 3.0TT engine. AWE’s patented 180 Technology resonators are the standout feature, eliminating drone-causing frequencies entirely while preserving raw performance character, and unlike traditional packed resonators, they won’t degrade in tone over time. On the dyno, this system delivered real-world gains of 13 hp and 12 lb-ft of torque at the wheels. Buyers can choose chrome silver or diamond black quad 4.5-inch double-walled, slash-cut tips to finish the look. Handcrafted in Pennsylvania from U.S.-sourced T304L stainless steel, the system is 100% emissions-friendly and comes with AWE’s Perfect Fitment Guarantee, No CEL Guarantee, and Lifetime Warranty — an unbeatable combination for serious enthusiasts.
- Patented 180 Technology eliminates drone completely
- Dyno-proven 13hp and 12lb-ft gains
- Handcrafted USA-made T304L stainless steel
- Perfect Fitment and No CEL Guarantees
- Exotic, rasp-free exhaust note
- Premium price point among these options
- GPF-equipped late-2026 models need fitment check
Expert Recommendation
If budget isn’t a concern, the AWE Touring Edition delivers the most refined sound engineering and strongest guarantees of any system on this list.
Stainless Works – Best American-Made Exhaust for Ford Explorer
Stainless Works built its reputation on American craftsmanship, and this 3-inch mandrel-bent catback system for the 2020+ Ford Explorer ST showcases exactly why enthusiasts trust the brand. Constructed from corrosion-resistant 304 stainless steel and TIG welded entirely at the company’s Streetsboro, Ohio facility, this system delivers an aggressive tone with zero drone, making it just as enjoyable on a daily commute as it is on a spirited backroad drive. Buyers can select between polished or black tip finishes to match their Explorer’s styling, and the system works seamlessly with either the factory downpipe or Stainless Works’ own high-flow downpipe for those chasing additional performance. Beyond sound, the smooth-bend 3-inch tubing is engineered to improve horsepower and torque while shaving weight and even helping fuel economy. Every unit is direct bolt-on for a true no-cutting installation. Backed by a lifetime warranty on both material and craftsmanship, this system is a strong choice for buyers who prioritize domestic manufacturing quality and skilled welding over mass-produced alternatives.
- 100% American-made, hand TIG welded
- Aggressive tone with zero cabin drone
- Compatible with stock or upgraded downpipe
- Lifetime warranty on material and craftsmanship
- Choice of polished or black tips
- Only fits Explorer ST, not other trims
- Higher price than mass-market brands
Expert Recommendation
Choose Stainless Works if domestic craftsmanship and premium TIG-welded construction matter as much to you as the exhaust note itself.
Flowmaster FlowFX – Best Horsepower Gains Exhaust for Ford Explorer
For Explorer ST and Aviator owners chasing serious dyno numbers, the Flowmaster Flow FX Cat-Back System delivers some of the strongest gains in this roundup — up to 20 horsepower and 25 lb-ft of torque at the rear wheels over stock. Manufactured from durable 409 stainless steel with 3.00-inch mandrel bent tubing, the system centers around a Flow FX series muffler featuring a built-in X-pipe style merge for an aggressive-to-moderate European exhaust character. Dual 3.50-inch black stainless steel tips finish the look with a custom, purposeful appearance. Flowmaster’s unique Helmholtz-style resonators help control interior resonance, keeping the cabin comfortable even under spirited driving. The high tuck design maximizes ground clearance, an important consideration for an SUV that may see light off-pavement duty. Installation uses all existing factory hanger locations, and the kit ships with complete instructions and hardware for a home-friendly install. Note that this system does not fit the Aviator Grand Touring with the hybrid engine. Backed by Flowmaster’s Lifetime Limited Warranty, the Flow FX stands out as the top choice for buyers who prioritize measurable performance gains above all else.
- Strongest gains: up to 20hp, 25lb-ft
- Built-in X-pipe for European exhaust note
- High tuck design preserves ground clearance
- Uses factory hanger locations for easy install
- Lifetime Limited Warranty included
- Not compatible with Aviator Grand Touring Hybrid
- 409 steel less corrosion-resistant than 304/T304
Expert Recommendation
The Flowmaster Flow FX is the pick for performance-focused buyers chasing the biggest measurable horsepower and torque gains on this list.
aFe Power MACH Force-Xp – Best for Maximum Power Exhaust for Ford Explorer
The aFe Power MACH Force-Xp Cat-Back System claims the top spot for raw performance on this list, with in-house dyno testing showing gains of up to 20 hp and 23 lb-ft of torque. Built from 2.5-inch mandrel-bent 304 stainless steel tubing, the system routes exhaust through a high-flow muffler tuned for a deep, unmistakable sound while unleashing all available power. Four laser-etched aFe POWER logo tips, finished in black powder coat, give the rear of your Explorer or Aviator a distinctive, aggressive stance. A heavy-duty flex pipe with an internal interlock liner adds strength and durability where the system needs it most, while factory-style hangers keep installation a genuine direct bolt-on affair with no cutting required. Every MACH Force-Xp system is 100% MIG-welded for race-proven durability and engineered using computer-aided design for tight, factory-level fitment tolerances. Manufactured at aFe’s Corona, California facility, this system doesn’t require a CARB EO number, and it stands as the strongest all-around performance option for buyers who care most about dyno numbers.
- Highest gains: up to 20hp, 23lb-ft torque
- Deep, powerful high-flow muffler sound
- Reinforced flex pipe adds long-term durability
- 100% MIG-welded construction
- Direct bolt-on, no-cut installation
- No lifetime warranty stated like competitors
- Bold sound may be too loud for some
Expert Recommendation
Choose the aFe Power MACH Force-Xp if maximizing horsepower and torque gains is your top priority over warranty length or subtle sound tuning.
Final Words
There’s something oddly satisfying about hearing an Explorer start up and realizing it no longer sounds quite so ordinary. You don’t need an obnoxiously loud system to get that reaction, either. The best exhausts give the Explorer a deeper, more confident voice while still letting you live with it every day. Whether you want a subtle rumble or something that announces itself when you step on the gas, the right system can make the whole SUV feel more alive.
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