Thread: TD5 exhaust setup.

The standard exhaust size 2.5" is plenty large enough for the TD5. For improvements do the following:

Replace the centre standard muffler with straight through high flow unit (personally I like Lukey brand). Remove or replace the rear tailpipe muffler with either the same or a hot dog.

Remove the cat converter, or replace with a high flow cat or hot dog if it has one.

And the often overlooked part is the restriction of the flexible piece in the down pipe from the turbo. The standard unit has a much smaller ID than the exhaust pipe. Replace with a larger one to get rid of this restriction.

Are you looking for more performance?

Originally Posted by twr7cx

The standard exhaust size 2.5" is plenty large enough for the TD5. For improvements do the following:

1 -Replace the centre standard muffler with straight through high flow unit (personally I like Lukey brand).

2 - Remove or replace the rear tailpipe muffler with either the same or a hot dog.

3 - Remove the cat converter, or replace with a high flow cat or hot dog if it has one.

4 - And the often overlooked part is the restriction of the flexible piece in the down pipe from the turbo. The standard unit has a much smaller ID than the exhaust pipe. Replace with a larger one to get rid of this restriction.

and start with number 4

Mine seems to be the older system without the cat, and the larger flex pipe.

How are people removing / replacing the flex joint?

I was just hoping to help it breathe a bit better and give it a refurb after 14 years of service. I haven't had any issues with the system, but thought changing out the mufflers may help this along, just seeing what others have done and how it went for them. Heading to Brisbane so just going over the car before we head off.

Originally Posted by RisingSun

Mine seems to be the older system without the cat, and the larger flex pipe.

Larger based on the actual ID or just what you assume from the OD?

I thought I read that the system that came on the 2000 model, the flex pipe had a larger internal diameter campared with the later system, that was the basis of my comment, only based on the difference between the older and newer systems on the D2.

Was still considering removing it as per the advice given, just wandering how others did it.

Originally Posted by RisingSun

just wandering how others did it.

Find a suitable replacement (through truck spares parts, or exhaust shop, etc.), remove downpipe, take to exhaust shop and ask them to cut the old one out and replace with the new, leave with them, go back and collect, pay, refit to vehicle, put tools away, have a beer.

The last step can be repeated several times if you like...

Or if you have your own welder pull it out and do the middle steps yourself...