The MBRP S6216409 (Armor Plus / XP Series) is a heavy-duty 4-inch turbo-back single-exit exhaust system engineered specifically for 2003–2005 Ford Excursions equipped with the 6.0L Powerstroke diesel engine. Fabricated from 100% 16-gauge T409 stainless steel tubing, this system delivers exceptional corrosion and rust resistance against harsh road salt and winter weather. MBRP outfits this complete exhaust package with a two-piece turbo downpipe, high-flow chambered performance muffler, Excursion-specific over-axle tailpipe geometry designed to clear the rear suspension and aft-axle 44-gallon fuel tank, OE-style welded hangers, and an angled mirror-polished 5-inch T304 stainless steel exhaust tip.

High exhaust gas temperatures (EGTs) while towing heavy trailers, severe turbo backpressure caused by the restrictive factory stamped 3-inch downpipe, choked power from dense OEM muffler baffles, sluggish turbo spool, and rust-through rot on factory components are what this system eliminates. The factory Ford 6.0L exhaust traps intense thermal energy directly behind the variable geometry turbocharger (VGT), driving up engine bay and cylinder head temperatures under load. The MBRP S6216409 opens up exhaust evacuation with smooth mandrel-bent 4-inch piping, dropping peak EGTs by up to 100–200°F, relieving backpressure on the turbine wheel, enhancing throttle response, and delivering MBRP's classic deep "Street Profile" exhaust note without excessive interior cabin drone. It is a complete 4-inch turbo-back exhaust kit including the downpipe, mid-pipe, performance muffler, over-axle pipe, tailpipe, 5-inch polished tip, and heavy-duty band clamps; catalytic converter delete pipes are sold separately.

It fits 2003–2005 Ford Excursion 4WD and 2WD models equipped with the 6.0L Powerstroke turbo diesel engine (engineered specifically to navigate the rear suspension and aft-axle fuel tank unique to the Excursion chassis; does not fit Super Duty pickup trucks).

Fitment

• 2003–2005 Ford Excursion 6.0L Powerstroke Turbo Diesel (4WD & 2WD)
• Engineered exclusively for the Ford Excursion SUV platform and aft-axle fuel tank layout
• Complete 4-inch turbo-back replacement exhaust system
• Includes a true two-piece 3.5" to 4" mandrel-bent turbo downpipe for easier installation clearance
• Fabricated from 16-gauge T409 stainless steel tubing for lasting corrosion resistance (XP Series)
• High-flow chambered performance muffler lowers EGTs while controlling in-cabin resonance
• Includes premium 5-inch OD angle-cut mirror-polished T304 stainless steel exhaust tip
• OE-style welded hangers mount directly into factory rubber chassis isolators
• Backed by MBRP’s Lifetime Warranty
• Complete exhaust kit including heavy-duty band clamps and installation hardware

Support the vehicle safely on a heavy-duty automotive lift or tall jack stands and disconnect both negative battery cables. Spray penetrating lubricant onto all factory exhaust flange bolts, rubber hanger isolators, and the turbo downpipe V-band clamp behind the turbo turbine outlet. Cut the factory downpipe using a reciprocating saw to facilitate removal from under the chassis, then loosen the factory V-band clamp to extract the upper downpipe section from the engine bay. Unbolt the catalytic converter and mid-pipe assembly, unhook the rubber hangers, and lower the original exhaust components out from under the Excursion. Install the upper section of the MBRP two-piece downpipe onto the turbo turbine discharge flange, loosely securing the factory V-band clamp before joining the lower downpipe section. Hang the high-flow performance muffler and intermediate pipe, then guide the over-axle pipe and tailpipe over the rear axle housing and around the aft-axle fuel tank shielding, inserting the welded hangers directly into the OEM rubber mounts. Install the 5-inch polished T304 stainless tip onto the tailpipe exit behind the passenger rear tire, align all pipe sections to ensure a minimum of 1 inch of clearance around brake lines, rear shock absorbers, sway bars, and the fuel tank heat shield, and torque all heavy-duty band clamps progressively from the turbo back to 35–40 ft-lbs.