The Thermal R&D B910-C910-C + A910 is a complete downpipe-back performance exhaust built specifically for the 2020 through 2025 Ford Explorer ST 3.0L EcoBoost. Using 2.5 inch T304 stainless steel mandrel bent tubing throughout, this system replaces everything from the OEM catalytic converter outlets back, increasing exhaust flow, deepening the exhaust note, and delivering a drone-free driving experience at highway speeds. All OEM hanger locations are used, no cutting or welding is required, and the tips are sized and positioned to fit cleanly within the factory rear valance.
One of the most common complaints with aftermarket exhausts on boosted SUVs is highway drone. Thermal R&D addresses this directly using their proprietary Helmholtz resonator technology, which cancels the specific resonance frequencies that cause drone at cruising speeds. Owners consistently report holding normal conversations and Bluetooth calls at 70 to 80 miles per hour without raising their voice. Under hard acceleration the system delivers a noticeably deeper, more aggressive exhaust note compared to the stock Explorer ST, which is widely considered acoustically underwhelming relative to the performance available from the twin-turbocharged 3.0 liter engine.
| Specification | Detail |
|---|---|
| Manufacturer Part Number | B910-C910-C + A910 |
| UPC | Contact us for UPC |
| Brand | Thermal R&D (Thermal Research and Development) |
| Pipe Diameter | 2.5 inch throughout |
| Material | T304 stainless steel, mandrel bent |
| Tip Size | 4 inch dual angle cut |
| Tip Finish | Black ceramic coated |
| Tubing Finish | Mill finish tubing and center muffler, brush finish rear muffler |
| System Type | Downpipe-back with front mid-pipes |
| Mounting | OEM catalytic converter outlets, OEM hangers |
| Installation | No cutting or welding required |
| Drone Control | True Helmholtz resonator technology |
| Country of Manufacture | USA (Lancaster, California) |
| Warranty | Limited Lifetime to original vehicle owner |
| Note | 2026 Explorer ST with Gasoline Particulate Filter may require additional fitment verification |
| Year | Make | Model | Notes |
|---|---|---|---|
| 2020 | Ford | Explorer ST | 3.0L EcoBoost, OEM downpipes required |
| 2021 | Ford | Explorer ST | 3.0L EcoBoost, OEM downpipes required |
| 2022 | Ford | Explorer ST | 3.0L EcoBoost, OEM downpipes required |
| 2023 | Ford | Explorer ST | 3.0L EcoBoost, OEM downpipes required |
| 2024 | Ford | Explorer ST | 3.0L EcoBoost, OEM downpipes required |
| 2025 | Ford | Explorer ST | 3.0L EcoBoost, OEM downpipes required |
Does this fit the 2024 and 2025 Ford Explorer ST?
Yes. This system fits the 2020 through 2025 Ford Explorer ST 3.0L EcoBoost. If you have a 2026 model year Explorer ST, verify whether your vehicle is equipped with a Gasoline Particulate Filter before purchasing, as GPF-equipped vehicles may require additional consideration.
Will this work with aftermarket downpipes?
This system is designed to mate directly with the OEM catalytic converters and factory downpipes. Some customers have paired it with aftermarket downpipes but fitment is not guaranteed with non-OEM units. Thermal R&D recommends OEM or OEM-style downpipes for the best fitment and sound.
Is there highway drone with the 2.5 inch Thermal R&D Explorer ST exhaust?
No. The Helmholtz resonator is specifically engineered to eliminate drone at highway cruising speeds. Owners consistently report zero drone at 70 to 80 mph and the ability to hold conversations without raising their voice.
How loud is the 2.5 inch system compared to stock and the 3 inch version?
The 2.5 inch system is noticeably louder and deeper than stock but remains comfortable for daily driving. It is quieter and less aggressive than the Thermal R&D 3 inch system, which is why it is the more popular choice among daily drivers. Both systems are drone-free at highway speeds.
Does installation require cutting or welding?
No. This is a direct bolt-in system using all OEM hanger locations. All necessary clamps are included. No cutting, welding, or drilling is required. Most owners with basic mechanical experience complete the install in a few hours.
Will this affect the check engine light?
No. The system mounts from the OEM catalytic converter outlets back and does not alter the catalytic converters or downpipes. Emissions compliance is maintained and no check engine light should result from a proper installation on a 2020-2025 Explorer ST with factory downpipes.
What is the warranty on this exhaust system?
Thermal R&D covers this system with a Limited Lifetime Warranty against defects in materials and workmanship for as long as the original purchaser owns the vehicle on which it was originally installed. The warranty does not apply to racing or commercial applications or improper installation. Under the Magnuson-Moss Warranty Act, a manufacturer cannot void your vehicle warranty solely because you installed an aftermarket exhaust component.
Will the black coated tips fit within the factory rear bumper valance?
Yes. The 4 inch dual angle cut black ceramic coated tips are specifically designed to fit within the OEM Explorer ST rear valance without any modification to the bumper or fascia.
Is this made in the USA?
Yes. Thermal R&D manufactures their exhaust systems in Lancaster, California using T304 stainless steel.
Is this system compatible with a tuned or modified Explorer ST?
Yes. The system is compatible with both stock and modified Explorer ST setups running OEM or OEM-style downpipes. Owners running larger turbos, intercoolers, or ethanol tunes have used this system successfully. For highly modified setups with non-OEM downpipes, contact us to confirm fitment.
Apply penetrating fluid to all factory exhaust clamps and hanger isolators before beginning. Starting at the rear, unclip the hanger isolators from the body-side rods and work forward toward the catalytic converter outlets. Disconnect the stock system at the OEM catalytic converter outlet clamps and remove in sections as needed. Install the front mid-pipe first, connecting at the OEM catalytic converter outlets and leaving clamps loose. Route the rear section into the OEM hanger locations, adjusting tip position and centering within the rear valance before torquing all clamps. Start the vehicle and check all connection points for leaks. No cutting, welding, or drilling is required at any point in this installation.
WARNING: This product can expose you to chemicals including nickel compounds, which are known to the State of California to cause cancer and reproductive harm. For more information, go to www.p65warnings.ca.gov.
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