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Review: Thermal R&D 3" Catback

Messages
7
Reactions
8
Points
2
Location
Atlanta, GA
Vehicle
2025 Explorer ST
#1
A couple of weeks ago, I upgraded to the Thermal R&D 3" Catback system to give my ST the sound it deserves. The stock exhaust felt underwhelming, likely because of government noise regulations, and as someone who’s owned high-performance cars, I really missed that powerful, aggressive tone.

After the installation, the difference was unmistakable. The car feels alive, with a fantastic cold start and a deep rumble on command—plus, no cabin drone, which is a huge plus. I’d rate it 5 out of 5 for sound and look.

That said, I might be getting a little more practical. My ST is my daily driver and family car, and there are times—like driving through the neighborhood at night or taking the family on trips—when the sound is a bit much. I’m wondering if a 2.5" version might have been quieter under normal conditions and only gone aggressive under wide-open throttle. I really appreciate the adjustable exhaust in my Corvette C7, where I can select the exhaust note with different driving modes, and even the stock sound of my RAM TRX is aggressive without being overwhelming inside the cabin.

Knowing what I know now, would I buy it again? Maybe. If a 2.5" offered a quieter sound in everyday driving with more roar on demand, I’d probably go that route. But for pure sound quality and presence, the 3" is still a great choice—just maybe more so if you’re less concerned about keeping things family-friendly.
 

Messages
1,347
Reactions
647
Points
162
Location
Nevada
Vehicle
'20 Raptor, '22 Explorer ST, '14 GT500, '03 F150
#2
You’re full of good writeups! I’m sure it will be very helpful to some people.
 

Messages
99
Reactions
33
Points
17
Location
Chicago IL
Vehicle
2022 Explorer ST
#3
I had the 2.5'' on my 2020 and I recently got the 3'' for my 2022. I went with the 3'' because I wanted a bit more volume, and I got it.

2.5'' IMO is perfect for the person that wants an aftermarket exhaust and is only loud when going WOT and moderately loud on cold starts (once warmed up, only a faint rumble). the 2.5'' still sounds great when revving it and when going WOT. With the 2.5'' I took many overnight trips across states while the family slept.

With the 3'', so far no complaints from the kid or the wife. But, they expected it, as I warned them this one might be a little loud.
 

Messages
34
Reactions
14
Points
2
Location
NJ
Vehicle
2023 Explorer ST
#4
Thermal is one of those absolute “must-haves” after buying an Explorer ST. I originally resisted, learned my lesson, and rectified the situation within a month.
 



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