The MBRP S6216AL (Installer 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% heavy-gauge aluminized steel, this complete replacement exhaust features smooth mandrel-bent 4-inch tubing to eliminate interior pipe flattening and flow restrictions. MBRP outfits the system with a two-piece turbo downpipe, a high-flow chambered performance muffler, an Excursion-specific tailpipe contour designed to clear the rear-mounted fuel tank, and OE-style welded hanger brackets that slip directly into factory chassis rubber isolators.

High exhaust gas temperatures (EGTs) while towing heavy trailers, extreme turbo backpressure caused by the flattened factory 3-inch stamped downpipe, restrictive OE catalytic converters and baffle mufflers, sluggish low-end turbo spool, and muffled exhaust sound 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 S6216AL opens up exhaust pathways, dropping peak EGTs by up to 100–200°F, relieving backpressure on the turbo turbine wheel, improving boost responsiveness, and unlocking the signature 6.0L variable-vane diesel exhaust tone. It is a complete 4-inch turbo-back exhaust kit including the downpipe, mid-pipe, performance muffler, over-axle pipe, tailpipe, and band clamps; polished or black stainless exhaust tips 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 chassis 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 clearance and flow
• Heavy-gauge 16-gauge aluminized steel tubing construction (Installer Series)
• High-flow, low-restriction straight-through performance diesel muffler design
• Dramatically reduces exhaust gas temperatures (EGTs) and exhaust backpressure
• Enhances low-end throttle response and turbo spool characteristics
• Utilizes factory OEM hanger locations without cutting or welding required
• Includes heavy-duty saddle/band clamps and installation hardware
• Exhaust system kit only (exhaust tip not included; accepts standard 4" inlet tips)

Support the vehicle safely on a heavy-duty lift or tall jack stands and disconnect both negative battery cables. Spray all factory exhaust flange bolts, rubber isolators, and the turbo downpipe V-band clamp generously with penetrating oil to loosen road grime and rust. From underneath the vehicle and inside the passenger-side wheel well, cut the factory downpipe using a reciprocating saw or remove the transmission crossmember support if attempting to pull it out intact, then loosen the factory V-band clamp at the turbo turbine outlet to remove the upper downpipe section. Unbolt the mid-pipe, catalytic converter, and muffler assembly, sliding the factory hangers out of the chassis rubber isolators. Install the upper half of the MBRP two-piece downpipe onto the turbo discharge flange, securing the factory V-band clamp loosely to allow for alignment adjustments before mating the lower downpipe section. Hang the high-flow muffler and over-axle pipe, paying close attention to clearance around the Excursion's rear sway bar, shock absorbers, brake lines, and rear-mounted plastic fuel tank heat shielding. Slide the tailpipe into position exiting behind the rear passenger tire, align all pipe sections to ensure a minimum of 1 inch of clearance around all underbody components, and torque the heavy-duty clamps evenly from the turbo back to 35–40 ft-lbs.