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Aero Exhaust Resonated Turbine XL Series Performance Muffler AT4040XL

$129.95 $132.00

Part Number: AT4040XL

Usually Ships Within: 24-48 hours FREE SHIPPING

Add An Optional 2004.5-2007 Dodge Ram Cummins Offset Pipe

From the Aero Exhaust Turbine Series comes the AT4040XL Diesel Exhaust Resonated Muffler. The original resonated Aero Exhaust Muffler design, the AT4040XL can be used on both diesel trucks and high-output gas engines with 4" piping. Designed for high-output diesel engines, the AT4040XL incorporates a sound-tempering resonator with the proven technology of Aero’s AT4040 turbine muffler into one unit. The AT4040XL utilizes Aero’s patented Air Foil technology giving your truck an incredible performance increase. Completely stainless steel — inside & out — the 4040XL is still versatile enough to be used with every American made passenger diesel truck — regardless of it’s make, model or year — tested on virtually every Ford PowerStroke, Chevy/GMC Duramax and Dodge Cummins. The AT4040XL is an excellent choice for any truck owner looking for performance & fuel economy increases while maintaining a tempered sound.

Aero Mufflers Pay for Themselves!

  • Up to 15% to 20% Increases in Fuel Economy!
  • 5% to 7% Increase in Horsepower and Torque!
  • Works with Virtually Any American Made Diesel Passenger Truck! see notes below
  • Significantly Reduces EGTs!
  • Resonated for a more Moderate Sound
  • Free FedEx Shipping!
  • Lifetime Manufacturer Warranty!
  • 30 Day Money Back Guarantee!

Check out these Aero Exhaust customer testimonials!

The Resonated Turbine Mufflers have a built-in resonator — before Aero’s patented Air Foil Cone — lined with high-temperature ceramic packing, ensuring a tempered exhaust tone with minimal effect on Aero’s famed performance increases. The Aero Turbine is based on jet engine and thermal-dynamic technology. The incoming exhaust airstream is rapidly expanded and split via an airfoil cone with an orifice similar to a jet engine. The outer airstream accelerates as it recombines with the inner airstream. The air then begins to spin, due to the velocity and air transfers. The recombining of the airstream creates a vacuum that both muffles the exhaust sound and increases the exhaust flow. The AT4040XL’s length allows for dual in-line mufflers on diesel trucks as well — actually increasing airflow & performance while reducing EGTs more than a single muffler system. No other muffler can make this claim – a true testament to the dramatic performance enhancements the Aero Exhaust AT4040XL Muffler provides.


NOTE: The 3 1/2" exhaust pipe
standard on most diesel trucks
can easily be bumped up to 4" or
replaced with a full 4" exhaust
pipe system. Please measure
before buying
so you know
what modifications may be needed.
INLET    :4.00" i.d.
OUTLET :4.00" i.d.
WIDTH    :6.00"
HEIGHT :6.00"
LENGTH :26.00"
WEIGHT :10.00 lbs.


Like all Aero Exhaust Mufflers, the 404XL is manufactured using the highest quality welded 304 hand-polished stainless steel, inside and out.The 4040XL has been successfully applied and tested on nearly every year, make and model of diesel truck on the market today. The 3 1/2" exhaust pipe standard on most Diesel trucks can easily be bumped up to 4" or replaced with a full 4" exhaust pipe system. Please make sure to measure before buying so you know if modifications will be needed.



NOTE: The AT4040XL, like all Aero Mufflers, is a straight through design. The stock muffler on 2004.5 through 2007 Dodge Ram 2500/3500 with the 5.9L Cummins diesel has an offset inlet and outlet. This offset pipe will allow for you to cleanly install the AT4040XL on your Dodge Ram.

If you want to enjoy increased performance, reduced EGTs & increased fuel economy, you need an Aero Exhaust Turbine today! Check out these test results to see how the Aero Exhaust has improved Car, Diesel, and Truck and SUV exhaust systems: