Exhaust Options - Catalytic Converter Ypipe and Exhaust pipe/muffler etc..

[searcherrr]

In the insane amount of hours/days I've spent researching various options for these Winnies as they are affectionately called I have found that there are limited options to replacing the Cats and the rest of the exhaust unless you'd go customized. I guess I'm looking for what most do.... direct-fit stuff. You could always use a torch to cut out your CATS and put some high-flows in there, but this article is about direct-fit.

So with that in mind I have found the following Direct fit Ypipe setups that include the CATS:

CATCO
Eastern Catalytic
Walker Exhaust Products
A Canadian Brand I could not identify on Ebay
Magnaflow
FORD OEM

As far as the rest of the exhaust I've only seen FORD OEM or 3rd party replicas at Autozone and Walker and because I've been looking for something that would yield more MPG and HP for a little bit better performance I stopped my search there for the rest of the exhaust system after only finding something discontinued.

Of the Cat brands I mentioned above the only one that I can identify that mentions a PERFORMANCE gain is the Magnaflow brand. The discontinued exhaust system I found is a BORLA performance cat-back exhaust system and to my knowledge (again without customizing) is the only direct-fit performance upgrade option available for the Winnies. I found one of those Borla's on Ebay and its on its way to me.

The only thing I'm concerned about is whether or not the 2nd muffler (which I guess replaces the resonator) will fit under the rear bumper area on my 95 due to the tow package I have installed as well as on my 95 the tailpipe curves and shoots out to the right instead of straight back like all Winnies 1999 and up.

I have confirmed that all years Windstar subframe DID NOT change and the method I used to confirm this was looking up the parts number for tow packages on Autozone.com and they all came up the same as did the part numbers for seating in the 2nd row. I'm only saying this to illustrate that the exhaust setup on all Windstars is nearly identical. I welcome to be told I'm wrong though if I am. lol

These are questions I'd like to hear back on:

1. Has anyone installed the Magnaflow brand Ypipe or even welded in any high-flow Cats to their Winnies? If so - MPG? Performance gains?

2. Respect for Magnaflow brand? Really more flow than stock?

3. Will it make a difference that will REALLY yield more power and get better MPG over the long run if I'd install the Magnaflow Ypipe?

4. Has anyone installed any other brand Ypipe or exhaust system therafter that was intended to be an OEM replacement and noticed better MPG and/or performance gains?

5. Has anyone installed the BORLA cat-back system I'm talking about and noticed any difference besides just SOUNDING COOL?

[wiswind]

I have the walker direct fit "Y" pipe, bought through rockauto.
I will say that the best unit would be the OEM......lowest price I found was just over $1200, plus shipping.
List price for the OEM is about $1600.
The walker has been just fine......and was about $321 several years ago.

My personal opinion would be to leave the OEM "cat back" alone unless it is bad....surface rust not an issue.
I really don't think you will gain much at all in performance and economy in changing it.

One thing to keep in mind......performance = very low fuel economy.
On the post 1995 3.8L windstars, we have the IMRC which adds a good 45hp......but I can tell you for sure that fuel economy is in the single digits whenever the IMRC is OPEN.
That is one thing that has stopped me from trying to boost the performance of my windstar.
Although my plan would have been to work out a bigger opening into the air filter "box"......keeping the stock air filter setup.
That point.....where the air passes through the fender, is the smallest air opening in the loop at wide open throttle.
But, again.....what small gain one would get......would not result in any improvement in fuel economy.

We already have a "cold air intake" as the air is drawn in from the fender behind the front tire.
I have verified this by the fact that the air input temperature, as measured in the flex tube between the throttle body and the MAF.....is within a couple of degrees of the outside air temperature.

So, my opinion......for what it's worth, economy is about the best that we can get with the stock components.......in good working order.

[searcherrr]

I guess I'm hoping that the new exhaust system would help with power just enough such that it doesn't disturb MPG. Like I hear what yer saying and it holds a lot of weight, but I'm wondering if the MPG would only be greatly reduced WITH the new exhaust setup IF the person started driving it around thereafter like a 16 year old with a new sports car vs just normal driving with the occassional burst of speed here and there.

Still if no one replies that they've done a new Borla direct fit exhaust or custom exhaust setup to verify info I'll not know until I do it myself.

FYI - I have the Kenny Brown article saved (off of Edmunds) from when he did all the upgrades to his Windstar and made it supercharged using the M90. He too added a bigger exhaust system, but may have only done so because he changed the intake setup to begin with. The only thing different on my intake is that I have a K&N filter in there. So I guess "possibly" like yer saying (you are probably right - lol despite my stubborness) a new exhaust system would be better suited to an upgraded engine bay as well. STILL - WE SHALL SEE.

I think I'm being so stubborn cause I've spent 5 years on the 3SI forum and everyone raves about how much better gas mileage and power they see once they upgrade their exhaust. Mind you that is a different platform and the cars weigh a little less we're still talking about automobiles which all work very similar from one to the next especially since the age of fuel injection. I have the NA 3000GT which is around 3200lbs, but the VR4 twin turbo's actually come very close to the 95 - 98 Windstar curb weights which I think are 3600 - 3800lbs. So if you use weight as a comparison factor PERHAPS.... MAYBE better MPG will result. I dunno. I won't know for sure until like I said.... till I try it. I was just hoping that someone may have done this already and have hard data. OK I'll stop being repetitious now and end this post. lol