Understanding Turbo-Back Exhaust Systems

A turbo-back exhaust system replaces every component from the turbocharger outlet to the tailpipe. Unlike cat-back systems that start after the catalytic converter, a turbo-back setup includes the downpipe, any intermediate pipes, the muffler, and the exhaust tip. By eliminating restrictive factory components — often a catalyzed converter or diesel particulate filter (DPF) on older trucks — these systems drastically reduce back pressure. The result is faster turbo spool, lower exhaust gas temperatures (EGT), and measurable gains in both horsepower and torque. Most systems are offered in either 4-inch or 5-inch diameters. A 4-inch system balances increased flow with retained low-end torque, while a 5-inch system maximizes top-end power and produces a deeper, more aggressive exhaust note. Keep in mind that on newer diesel trucks with complex emissions controls, a full turbo-back installation may require aftermarket tuning and is often intended for off-highway use only.

When shopping for a turbo-back system, material quality matters. Options include aluminized steel (durable and economical) and 304 stainless steel (corrosion-resistant with a polished appearance). Mandrel-bent tubing maintains consistent diameter throughout for optimal flow, and a free-flowing muffler or resonator can reduce drone without killing performance. Below are five of the most popular systems on the market, each with specific sizing and power enhancements that align with different budgets and performance goals.

1. MBRP Turbo-Back Exhaust System

MBRP has built a strong reputation among diesel owners for offering reliable, street-legal systems at a competitive price point. Their turbo-back systems are engineered to bolt directly to the factory turbo outlet, making installation straightforward for a weekend mechanic. MBRP uses heavy-duty 16-gauge aluminized steel in most kits, though a 409 or 304 stainless upgrade is available for those in corrosive environments.

  • Sizes: Available in 4-inch and 5-inch diameter options.
  • Power Enhancement: Claims a 10–15% increase in horsepower and a similar improvement in torque, depending on the specific engine and tuning.
  • Sound: Produces a deep, mellow tone at idle that opens up to a muscular roar under full throttle. The addition of an optional muffler reduces interior drone.
  • Notable Features: Uses mandrel-bent tubes for smooth flow, heavy-duty hangers, and a polished stainless steel tip. Many kits include a high-flow catalytic converter option for street-legal compliance.

For drivers who want a proven product without breaking the bank, the MBRP system delivers consistent results. Pairing it with a mild performance tune can push total gains past 50 hp on trucks like the Ford Power Stroke 6.7L or Ram Cummins 6.7L. You can find detailed fitment guides and dyno charts on MBRP's official site.

2. Flo-Pro Turbo-Back Exhaust System

Flo-Pro focuses on reducing back pressure while keeping the installation hassle-free. Their systems are known for mandrel-bent, smooth-flowing tubes that eliminate the sharp bends found in some factory pipes. This design is especially beneficial for diesel trucks that tow heavy loads, as lower EGTs help protect the engine under sustained stress.

  • Sizes: Offered in 4-inch and 5-inch configurations.
  • Power Enhancement: Provides significant boosts to torque at the mid-range, with peak horsepower gains often landing in the 20–40 hp range after tuning.
  • Sound: A moderately aggressive tone without the tinny rasp common on cheaper systems. Flo-Pro uses a free-flowing muffler that quiets highway cruising noise.
  • Notable Features: Heavy-duty 16-gauge aluminized steel; all necessary clamps and hangers are included. A stainless steel tip is optional.

Flo-Pro’s system is a solid middle-ground option. It competes directly with MBRP in price but often delivers a slightly quieter interior volume, making it a favorite for daily drivers who want performance without a constant cabin drone. For full specifications and vehicle-specific fitment, refer to Flo-Pro’s website.

3. Banks Power Monster Exhaust System

Banks Power is synonymous with engineering-driven diesel performance. The Monster Exhaust system is designed not just to flow more air, but to create a scavenging effect that reduces back pressure and speeds up turbo response. Banks uses a patented design known as "TorqueTube" technology in some of their kits, which blends the downpipe and intermediate pipe into a single, aerodynamically shaped unit.

  • Sizes: Typically available in 4-inch diameter, with some heavy-duty applications offering 5-inch.
  • Power Enhancement: Gains vary by engine, but independent tests on 6.6L Duramax and 6.7L Power Stroke trucks have shown a 10–20 hp increase and up to 30 lb‑ft of torque at the wheels with no other modifications.
  • Sound: A deep rumble that emphasizes the turbo spool; Banks engineers work to eliminate harsh drone at highway speeds.
  • Notable Features: Includes a high-flow muffler that is still street-legal in most states. The system is backed by extensive dyno and real-world testing.

Banks often targets the enthusiast who is willing to pay a premium for refined sound and proven engineering. If you own a newer truck with emissions controls, Banks also offers a “Monster Route” system that integrates with the stock DPF and SCR to maintain a street-legal profile while still improving flow. Explore the full lineup on Banks Power’s official page.

4. AFE Power BladeRunner Exhaust System

AFE Power (Advanced Flow Engineering) is respected for their high-end intake and exhaust components. The BladeRunner series is their latest turbo-back offering, built around large-diameter, mandrel-bent tubing and a wide selection of tips, including polished stainless, black ceramic, and carbon fiber options. AFE Power systems are designed to be a direct bolt-on with no cutting required.

  • Sizes: Available in 4-inch and 5-inch diameters for most applications.
  • Power Enhancement: Improves throttle response and overall engine breathing. With a programmer, total gains can exceed 40 hp on equipped trucks.
  • Sound: An aggressive, yet refined tone. AFE uses a straight-through resonator and muffler to keep volume under control while maximizing flow.
  • Notable Features: Constructed from 409 stainless steel (with 304 stainless upgrade). Includes a lifetime warranty on the stainless models. Clamps and hangers are provided for a clean install.

AFE Power is a top pick for owners who want a polished show-quality system that also delivers real-world performance gains. The availability of custom tip finishes allows for personalization. Check AFE Power’s website for detailed fitment guides and dyno results specific to your diesel truck.

5. Gibson Performance Turbo-Back Exhaust System

Gibson Performance has been building aftermarket exhausts for over 30 years, focusing on street-legal systems that offer a distinctive sound and easier installation. Their turbo-back kits come with a high-flow catalytic converter that meets emissions requirements on late‑model trucks, making them a smart choice for those who cannot delete their emissions equipment.

  • Sizes: Offered in 4-inch and 5-inch variants.
  • Power Enhancement: Gains are modest on a stock truck (5–10 hp), but when paired with an intake and tuner, customers report increases of 30 hp or more.
  • Sound: A deep, aggressive exhaust note that is louder than stock but not overbearing. Gibson includes a large free-flowing muffler to prevent drone.
  • Notable Features: 16-gauge aluminized steel; mandrel-bent; uses factory hanger locations. The system is backed by a limited lifetime warranty.

Gibson’s value proposition lies in its balance of cost, sound, and street legality. For drivers who want to keep their truck compliant with local emissions laws while still enjoying a performance exhaust note, the Gibson turbo-back is an excellent option. Learn more about specific fitments at Gibson Performance’s site.

Choosing Between 4-Inch and 5-Inch Diameter Systems

The primary decision when selecting a turbo-back exhaust is pipe diameter. A 4-inch system is the standard choice for daily-driven trucks that tow or haul. It provides enough flow to support mild to moderate tuning (up to 150–200 hp over stock) while preserving low-end torque. The sound is deeper than stock but not oppressively loud.

A 5-inch system is for high-horsepower applications — often beyond 500 wheel horsepower. The larger diameter reduces back pressure at high RPM, allowing the turbo to breathe freely and produce more top-end power. However, a 5-inch system can sacrifice a small amount of low-end torque and may be louder inside the cab. It is generally recommended only for trucks that see heavy track use or extreme competition. Before purchasing, verify clearance under the chassis: some lifted trucks can accommodate 5-inch exhaust easily, while stock-height trucks may require additional hangers or trimming.

Conclusion

Upgrading to a turbo-back exhaust system is one of the most effective mods for unlocking the true potential of a diesel truck. Each of the five systems reviewed here offers distinct advantages: MBRP delivers value and proven reliability; Flo‑Pro prioritizes a drone-free interior; Banks Power provides refined engineering and turbo response; AFE Power offers premium materials and customization; and Gibson Performance keeps the system compliant for street use. Regardless of which you choose, the combination of reduced back pressure, improved exhaust flow, and a more aggressive sound will transform both the performance and the character of your diesel truck. Pair your selected exhaust with a quality intake and a calibration upgrade for the greatest gains. As always, check local regulations regarding emissions equipment before installation, and consider professional installation if you are not comfortable with exhaust work.