I have an '06 4.0 ranger 4x4 ext. cab. I am working out of state, and my ranger is not with me. I'm looking at exhaust parts online, but since I can't crawl under my truck to look at the exhaust i have the following questions: If memory serves, there is a flange on the exhaust after the cats, before the muffler. I think at the flange the diameter of the pipe changes from 3in to 2.5in. So here's what I have in mind, I want to install a Flowmaster 943044 - 40 Series Delta Flow Muffler. This is a 3 inch offset inlet / 3.00 same side out muffler. I would like to install a flange between the cats and the muffler, and another flange after the muffler, with a flanged turn down. Will I need 3 flanges, or just two? I'm not sure if I can make use of the flange closest to the cats, or do I need to cut that off and replace it to maintain a 3 inch inside diameter? I plan to stand the muffler up on it's side long ways, rather than lay it flat. I've attached pics of the parts I have in mind. Any advise/suggestions would be appreciated. I have future plans of installing a cold air intake and an Eaton M90 supercharger.

 

.Going through this at the moment myself as well. The pipe coming out of the cats is 2.5" not 3", at the end of that it necks down to 2" before the flange. I would cut that flange off and have a 2.5" flange welded on so you don't have the bottle neck at the stock flange. The pipe is not directly in line with the frame rails, it angles slightly down and in twards the drive shaft as it passes under a cross member. You would need a slight bend in your new pipe to make it under the cross member. You should have enough room to stand that up on end if you move it back far enough. I am laying mine flat so it will fit under the cab, you would need to move yours under the bed to stand it up. There will be @ 2-2.5' run of pipe between the cats and the muffler. I don't think you need 3 flanges, 1 at the joint between the old pipe and the new pipe should be good. You can buy those turn down tips and have them welded directly to the muffler. Be aware that you will have to have some custom hangers made because there are no stock hangers between the cats and the exit of the stock muffler. My plan is to move my muffler forward then have a 90* bend on the exit and bring the tip out under the bedside in front of the tire. Hope this helps.

 

Thank you! This is very helpful. I am out of state and don't have my Ranger with me and was wanting to order these parts online so they would be waiting for me at home when I get there. Hopefully the 2.5" parts will be a little bit cheaper than the 3".

 

Turns out my cats are clogged up (it's in the shop right now). I'm still out of state and unable to crawl under my truck to have a look at things. Are the pipes between the manifolds and the cats 2.5 inch or 2.25? Looking at aftermarket high-flow cats. Do my stock cats have air tubes? And does the '06 4.0L have EGR?