Off-Road Exhaust 101: Features and Benefits to a 4×4 Exhaust System

Today’s off-road exhaust systems feature many innovations forged through years of trial-and-error. While these advancements translate to better torque, fuel efficiency, and power for off-road adventures, they also create a host of exhaust options to choose from. To help with the decision-making process, we here at The Engine Block compiled some useful guidance on how to buy the right exhaust system, at the right time, for the right purpose.

A Little Off-Road Exhaust History

Engine development has evolved considerably since 1967, back when the concept of off-road performance really began to emerge. Where original off-road powerplants leaned more toward hotrod methods than dirt-racing approaches, the goal was nevertheless the same: get there as quickly as possible, overcome the terrain, and survive to tell the tale first.

As you might expect, exhaust development evolved alongside under-the-hood power. Initially, systems applied traditional manufacturing and tuning methods because there wasn’t anything else to go with at the time. But year-by-year and event-by-event, newly professional off-road folks refined their own hard-earned art.

Many early exhaust configurations utilized stock under-slung hangers and bushes. Then, over time, short scavenge pipes began to emerge. These types were further enhanced by mandrel-fabricated piping in all kinds of materials and configurations – more typically upswept, or those that were bent parallel with the insides of frame rails, to avoid hitting rocks, berms, or other natural obstructions at speed.

As engine tuners began to optimize the balance of outright power against torque, exhaust length became important too. Remember, the goal isn’t to hit the gas and simply power through. That low-end torque is critical, as it makes quick work of trail obstacles, and provides reliable grip on soft or sloppy ground.

With that last point in mind, let’s address why your vehicle’s stock exhaust is not cut out for off-road excursions.

Why Do I Need A Specialized Off-Road Exhaust?

Just like grippy tires, a good lift kit, and a quality winch will keep you up and out of trouble on the trail, an off-road exhaust system is specially designed to tackle rough terrain. Consider how you huff and puff when hiking up the face of a rocky hill, as opposed to strolling down a paved road, and you’ll start to see how our vehicles require a little extra breathing power too.

Off-Road Exhaust Benefits

Better construction. Factory exhausts are built with OEM bottom lines in mind – not long-term abuse. Aftermarket off-road exhausts utilize more durable materials (like stainless steel) that can stand up to rocks, ruts, and rust.

Better airflow. Similarly, stock exhausts are formed through compression bending, which creates pinches along the contours. This technique is cost-effective, but it slows down exhaust gas velocity and hurts horsepower and torque. Most quality aftermarket exhausts use mandrel-bent tubing, which keeps the pipe from being crushed at the contours, translating to better engine performance and less heat generation.

Better clearance. Those low-hanging stock components are just waiting to catch on a rock or tangle of gnarled roots. Even a mild off-road exhaust system will prioritize higher clearance, tucking up the exhaust tips so you can still get dirty on the trail.

Better Sound. With less restrictions on the exhaust piping, your engine can properly bellow its presence. For many off-roaders, a deep and throaty exhaust tone is just as much a badge of honor as that 2-inch layer of mud, grit, and clag all over a rig’s exterior.

The all-new Bronco Trail Kit Exhaust from Gibson Performance Exhaust is built for Bronco enthusiasts who take off-road capability, obstacle clearance, and performance seriously.

The Buyer’s Choice

Now that you know why a specialized exhaust system is in order, we can move onto how you go about finding the right setup. The easiest way is determining what you plan to do with it.

There are many different flavors of off-roading, and each riding style has different needs. For example, if what you want is just a bit of power added to your daily driver so you can handle occasional weekend wheeling, then a single exhaust system will provide some additional pop, while not shaking the entire neighborhood apart when it comes to sound level. On the other hand, if you’re planning to regularly climb rocks or hit muddy forest trails, then something more robust is in order. A dual split rear exhaust will help your system breathe better, so you can test your mettle in Moab without losing the ability to still pass on the highway.

Note: Speaking of highway driving, depending on which state you’re in, emissions and sound mitigation are critical elements to consider when buying any aftermarket exhaust system. For example, most states stipulate specific dB (decibel) levels for on-road operation. So, if you plan to use your off-roader for daily driving, first ensure that your exhaust upgrade meets any necessary road-legal requirements.

Below are some important features to inspect when shopping for an off-road exhaust.

Construction

As previously mentioned, the material difference between stock and aftermarket exhaust systems is considerable. The same is true when comparing individual suppliers in the parts store aisle.

Not all off-road exhaust systems are made equal. Plated or coated options might save you money upfront, but they are not built to last and consequently, will cost you in the long run. Instead, look for systems constructed of stainless steel or aluminized steel. Both are strong, will stand up to corrosion, and produce a great exhaust note. However, if you live in a particularly harsh climate – or plan to off-road in one – stainless steel is the best choice, as it can better withstand Mother Nature’s ire (and northern municipalities’ love of road salt).

If your off-road rig is an older model, and you don’t intend to keep it for a long time, then a less expensive aluminized steel system makes more sense. As noted, it will still provide excellent strength and performance, but its shorter lifespan will better match that of your aging vehicle.

Configuration

Here is where your off-road identity plays a starring role. Are you a rock crawler? Do you race hill climbs? Are you a desert racer, or all of the above?

Each exhaust system installation style applies directly to its purpose. So, if you’re rock-crawling, you’ll want piping that is out of the way, where running hill climbs and desert events will also require ready placement, and/or replacement inside the frame rails.

Generally, when shopping, cat-back exhaust systems will dominate your search results. However, you may also find products labeled header-back, axle-back, turbo-back, or filter-back. These terms refer to the point where the exhaust system installs. So, header-back systems replace everything from the headers to the tailpipe, while cat-back systems replace everything from the catalytic converter and back. Axle-back concern only what’s behind the axle, and so on and so forth.

For a detailed rundown on the features and benefits of these different exhaust system types, as well as expected installation commitments, check out our comprehensive aftermarket exhaust system buying guide.

Where your exhaust pipe exits will also play a role in how your system performs off-road.

Some configurations you should be familiar with include:

Single Exhaust. The most common type of exhaust, this system features one single pipe which exits at the rear bumper on the passenger side.

Dual Rear Exit. Lending a sportier style, this exhaust configuration uses two exhaust pipes that exit on opposite sides of the vehicle, at the rear bumper.

Opposite Dual Exhaust. This configuration uses two separate pipes, similar to the dual rear exhaust above, but routes them to exit behind your vehicle’s tires. Large, heavy trucks (especially those that do a lot of towing) often feature this style.

Dual Side Exhaust. In this configuration, two exhaust pipes sit next to each other and exit on the vehicle’s side, near the rear bumper.

Note: Some avid off-roaders opt for a single or dual side exit system that dumps before the rear axle. This helps prevent potential damage to the exhaust system when the rear bumper dips on rugged terrain.

Sound

It’s unlikely you’re choosing an off-road exhaust system solely on its sound quality, but certain systems will sing sweeter than others. On the whole, dual setups provide a deeper and throatier sound. However, you can alter your driving experience further by tweaking your system’s muffler, adding a resonator, or involving a delete pipe capability.

A general rule of thumb: A muffler will be your quietest option, as it “muffles” the sound, while a resonator adds some subtle aggression and a delete pipe will most certainly turn heads.

Meet Gibson Peformance Exhaust

Regardless of whether you’re looking for a complete exhaust system, individual exhaust components, mufflers, or styling items like pipe tips, Gibson Performance Exhaust fits the bill.

While its roots are in RV exhaust systems, the company quickly became a household name for 4×4 enthusiasts. Gibson’s cost-effective performance systems captured consumer attention in the early ‘90s when the aftermarket category first emerged in the sedan, truck, SUV, and off-road sectors. Since then, the family-owned company has committed itself to ensuring that every exhaust product offers maximum power and torque, direct extension of mileage, and proven quality throughout. Emissions-certified in every state, Gibson systems also offer limited lifetime warranties, and feature hassle-free bolt-on installations.

Along with its complete and specific exhaust systems Gibson Performance also offers a range of complimentary accessories including; headers, standalone mufflers, and branded apparel items, while always offering various product close-outs.

Whether you’re a novice, daily-driver, professional racer, or truck owner whose requirements fit someone in between, when it comes to performance exhaust components for the on-road performance or off-road sector, check out everything Gibson offers. You’ll be happy you did.