aFe Large Bore-HD Cat-Back Exhaust System

2004–2007 Dodge Ram 2500 / Ram 3500

49-42002

Overview:

The aFe Large Bore-HD Cat-Back Exhaust System is engineered specifically for 2004 to 2007 Dodge Ram 2500 and Ram 3500 trucks, delivering a significant upgrade in exhaust flow and overall performance. Designed for enthusiasts seeking aggressive sound and enhanced power, this system replaces the factory exhaust with mandrel-bent 409 stainless steel tubing and offers a single side exit with a polished tip for a clean, professional look. Whether you want to improve horsepower, torque, or reduce exhaust gas temperatures, this cat-back system provides a durable and effective solution.

Ideal for heavy-duty applications, the Large Bore-HD system is built to withstand demanding conditions while maximizing engine efficiency and responsiveness. It’s a direct-fit upgrade that balances performance gains with a bold exhaust note.

Key Features:

This exhaust system combines advanced engineering with high-quality materials to deliver reliable performance improvements and a distinctive sound. Key features include:

• 4-inch mandrel-bent 409 stainless steel tubing for maximum flow and durability
• High-flow, straight-through perforated muffler measuring 8" diameter by 30" length
• Includes a muffler delete pipe option for a more aggressive exhaust tone and increased flow
• Polished stainless steel exhaust tip for a sleek, finished appearance
• Bayonet-style hangers with swaged ends for secure, rattle-free installation
• Slotted and swedged pipe ends paired with premium band clamps to ensure a tight, leak-free seal
• Designed and tested on flow benches and dynamometers to optimize pipe diameter and muffler construction
• Improves exhaust flow by up to 29%, reducing exhaust gas temperatures by up to 100°F
• Constructed in the USA with a 2-year limited warranty

Construction & Design:

The Large Bore-HD Cat-Back Exhaust System is crafted from durable 409 stainless steel, chosen for its excellent corrosion resistance and strength under high-heat conditions. All tubing is mandrel bent to maintain consistent diameter through bends, preventing flow restrictions common with crush-bent pipes. This ensures smooth, unrestricted exhaust flow and maximizes performance gains.

Each hanger is fully welded on both sides and features swaged bayonet ends to lock securely into factory mounting points, providing a stable and vibration-free fit. The system uses slotted and swedged pipe ends combined with premium band clamps to create a tight seal that resists leaks over time. The two-piece tailpipe design allows for precise adjustment during installation, ensuring proper alignment and fitment.

Performance & Sound

Engineered to enhance both power and sound, this cat-back system increases exhaust flow by up to 29%, which contributes to improved horsepower and torque output. Additionally, it lowers exhaust gas temperatures by as much as 100°F, helping to maintain engine efficiency and longevity under heavy loads.

The included straight-through perforated muffler delivers an aggressive and loud exhaust note that complements the truck’s heavy-duty character. For those seeking an even more pronounced sound and maximum flow, the system includes a muffler delete pipe option, allowing you to tailor the exhaust tone to your preference.

Installation & Fitment:

Designed as a direct bolt-on replacement for the factory exhaust, the aFe Large Bore-HD Cat-Back Exhaust System installs using existing factory mounting points with no modifications required. The system includes all necessary clamps, hangers, and detailed instructions to facilitate a straightforward installation process. The two-piece tailpipe design allows for easy adjustment to achieve perfect alignment and clearance.

What's Included:

• 4-inch mandrel-bent 409 stainless steel tubing
• 8" diameter by 30" length straight-through perforated muffler
• Muffler delete pipe for aggressive sound option
• Polished stainless steel exhaust tip
• Premium band clamps
• Bayonet-style hangers with swaged ends
• Detailed installation instructions

Ideal For:

This exhaust system is perfect for Dodge Ram 2500 and 3500 owners from model years 2004 to 2007 who want to enhance their truck’s performance, sound, and durability. It is especially suited for heavy-duty users who demand improved horsepower and torque for towing, hauling, or off-road applications, while also appreciating a bold, aggressive exhaust tone.

aFe POWER (Advanced FLOW Engineering) offers dyno-proven intake, filtration, and exhaust upgrades aimed at measurable performance gains. The brand’s lineup is geared toward enthusiasts looking for better airflow, improved sound, and durable materials—from cold air intakes to stainless exhaust systems for street and track applications.