⚠️ Important: Certain exhaust components or systems may not be compatible with Gasoline Particulate Filter (GPF) equipped vehicles. Please see our GPF Identification Information for full details.

2025+ Explorer /Aviator 3.0L Catted Downpipes by Kooks Headers

Note: *** Kooks is a built to order manufacturer and while typical lead time is 6-8 weeks, some products may take up to 12 weeks to produce.***

Key Features:

304 Stainless Steel Construction
Connects to OEM/Aftermarket Mid-pipes.
Kooks GREEN Cats EPA verified 400 Cell High Flow Catalytic Converters
Kooks GREEN Cats are engineered to perform in Modern Muscle cars up to 750 RWHP
Highly recommend the use of the 9003A.

Specifications

Material	304 Stainless Steel
Tube Diameter	1.875 in.

2025+ 3.0L Explorer ST/Aviator Kooks GREEN Catted Downpipes

SKU: 15123300

$1,540.50

$1,386.45

Parts Package Discount

Quantity

2025 - 2026 Ford Explorer ST 3.0L

2025 Lincoln Aviator Black Label 3.0L

2025 Lincoln Aviator Reserve 3.0L
WARNING: This is a Competition Use ONLY Product manufactured and sold for installation on vehicles to be used solely for competition motorsports, which, once such product is installed, may never be used, or registered or licensed for use upon a public road or highway. Any other use, including recreational off-road use, may be in violation of local, state, and Federal laws. ZFG Racing LLC does not implicitly or explicitly confirm the legality of using any products it sells on public roads; that is entirely the responsibility of the consumer. If a Competition Use Only Products is installed on a vehicle and that vehicle is used on a public road or highway, it may be considered in violation of the Clean Air Act and personally subject to substantial civil penalties.
Performance Benefits

Upgraded downpipes allow the turbocharger(s) to spool up faster and maintain more boost than stock downpipes, resulting in increased power output and better overall engine performance. This upgrade also improves throttle response, and provides a more responsive and powerful driving experience.

Enhanced Exhaust Flow and Reduced EGTs:

High flow cats are designed to allow exhaust gases to pass from the engine and turbos more freely compared to stock catalytic converters, resulting in a reduction of backpressure and a reduction in exhaust gas temperatures (EGTs).

The use of mandrel bent tubing ensures smooth exhaust flow post-cat, which maintains reduced back pressure and exhaust gas temperatures (EGTs) for optimal performance.

Better Flow = Faster Spool = More Boost:

Reduction of EGTs and decreased backpressure allows turbocharger(s) to operate more efficiently in terms of spool time and building boost.

Build Quality:

High-Quality T304 Stainless Steel

Downpipes constructed from 304 stainless steel offer superior durability and resistance to corrosion, ensuring long-lasting performance.

Terms & Conditions: Please see our Terms & Conditions for complete details.

Custom tuning files and services are non-refundable and non-transferable!
You may not use your custom tuning file on any other vehicle or transfer our service, used or unused, to any other customer.

Merchandise Returns will only be accepted within 30 days of the customer receiving the product, and ONLY if a Return Merchandise Authorization (RMA) has been issued.

RMA must be requested via email to sales@tunedbyzfgracing.com
Returns must be brand new and in their original, unopened packaging.
A restocking fee of up 25% may be applied to all items sold on this website or invoiced by ZFG RACING LLC. Restocking fees are TBD and agreed upon at time of RMA issue.
Special order items and electronics are not able to be accepted for return.
If a customer changes an address, or enters an incorrect address, when placing the order, the customer is responsible for any address change/correction fees billed by the carrier.

Order Cancellations are subject to a 5% cancelation fee.

Cancelation fee to be determined at the time of cancelation.
Cancellations must be requested via email to sales@tunedbyzfgracing.com

⚠️ Important

ZFG Racing does NOT sell or ship to the State of California
Orders outside the Continental USA must be requested via invoice

📦 Order Processing & Shipping

Lead times vary by item and manufacturer
Please allow 3-6 business days for order processing
Most parts are shipped directly from the manufacturer or supplier
Tuning devices and select items ship from ZFG Racing
Orders may arrive in multiple shipments

🌎 Shipping Locations

Continental USA orders can be placed directly through the website
Shipping rates are calculated at checkout
For Alaska, Hawaii, APO/FPO, U.S. Territories, or international:
→ Submit a Request for Invoice with full address details (city, state/province, and postal/ZIP code)

📬 Order Updates

Shipping updates will be sent via email once available
Updates are also available in your ZFG Account→ Order History

❓Questions → Feel free to email us at sales@tunedbyzfgracing.com - include the product link, part number or your order number for reference.

After you place your order: Tuning Package (with device): – Your RTD device will ship after processing – Most devices are delivered within ~1 week Tune Only: – No shipment required – You can get started📘 right away Additional Tune / Tune Updates & Upgrades: – No shipment or new files required – Submit a Tune Request to begin 📘 Getting Started (Required for New Customers) Review Pre-Tune Preparation for recommended mechanical checks ✅ Follow the Quick Start Guide before moving on: Set up the TDN app Link ZFG Racing as your tuner (enter code: TFWP-6913 in the TDN App) Read your stock file Note: If you encounter any issues while reading your vehicle, please follow the guide and retry the process before submitting your request 📩 Next Step (Required): Submit your Tune Request through Tuning Central We cannot begin your tune until this is submitted 🔁 Tuning Process: Custom tuning is revision-based Your final file is built using your data logs Most tunes are completed within ~2 weeks after your first submission

The information below is relevant to all vehicles (regardless of condition or mileage) ✅ Confirm vehicle is mechanically sound ✅ Verify fluid levels ✅ Verify battery health / voltage stability ⚙️ See What mechanical checks do you recommend? for full details on the recommendations above. 🔧 Install available modifications You are not required to have mods installed before tuning If you do have parts on hand, install them prior to submitting logs See FAQ: Modifications → Recommended modifications & Should I wait until parts are installed? for more detail 🔍 Check for prior modifications or tuning (pre-owned vehicles) If the vehicle was purchased used, verify whether it has been previously tuned If you know the vehicle has been tuned, we strongly recommend having it flashed back to stock by a Ford Service Department before starting the tuning process. If you are unsure: We can often identify whether the ECU has been modified once your stock file is submitted These cases are handled case-by-case during the review process Starting from a confirmed stock baseline is strongly recommended. Known or unknown prior tuning can impact results and may introduce inconsistencies during the tuning process. Keep our recommendations handy with this PDF:

✅ The information below is relevant to ALL vehicles (regardless of condition or mileage) 💧 Verify fluid levels Transmission: Fill to ~3 on the dipstick (note: known to come under-full from the factory) Engine Oil: ~0.5 qt over standard fill Top off all other fluids as needed ⚡️ Verify battery health / voltage stability Ensure battery is fully charged and in good condition Low voltage can cause flashing issues or inconsistent logs ⚙️ Verify spark plugs If replacements are needed, we recommend going to a step colder plug We recommend the NGK 95605 gapped to 0.028" ⚠️ Address existing codes first Even if unrelated, we recommend resolving any stored or pending DTCs before tuning Keep our recommendations handy with this PDF: Product Recommendations:

📱 Device / app readiness Confirm your RTD / MPVI device is updated and recognized Download and log in to the HP Tuners TDN app prior to starting 📊 Safe logging conditions Perform logs in a safe, controlled environment Find a flat, open road with minimal traffic ⛽ Use the correct fuel Run the fuel type your tune is for (e.g., 93, E30, etc.) If switching fuels, allow time for the new fuel to fully circulate before logging 🌡️ Bring vehicle to operating temp Do not perform logs on a cold engine Recommended transmission temp 170*+ 🧾 Submit complete Tune Request (through Tuning Central) Complete & update your Member Profile to pre-fill Tune Requests Ensure all fields are filled out accurately and completely Mismatched info (fuel, mods, etc.) can delay revisions

Proper maintenance is key to ensuring your vehicle runs safely, reliably, and performs at its best with your custom tune. We recommend staying on top of the following items, specifically: Engine oil: Check regularly and run ~0.5 quart over (especially if launching or driving aggressively) Service intervals: Shorten intervals and stay ahead of routine maintenance Fluids: Check levels consistently and adjust as needed (engine, trans, etc.) Remember: • Tuning can’t fix mechanical issues • Mechanical issues won’t always show in logs • Overall vehicle condition directly impacts performance For full details, please refer to our Maintenance & Fill Recommendations guide. Your tune file notes and any direct guidance from our team always take precedence. Additional Considerations: Spark Plugs & Ignition Health Maintain properly gapped, quality spark plugs and ensure ignition components are in good condition—this becomes increasingly important on higher-power setups. We recommend the NGK 95605: Overall Vehicle Health Address any underlying issues promptly, as the tune is designed around a properly functioning vehicle Hardware Changes If you plan to modify or install additional parts, we recommend reaching out before aggressive driving so we can confirm compatibility with your current calibration For additional detail, we provide a Maintenance & Fill Recommendations guide as a reference. Please note: Your tune file notes and any direct guidance from our team will always take precedence.

Before making any hardware changes, we recommend reaching out so we can review your setup and confirm compatibility with your current tune. Your calibration is built around your existing configuration, and even small changes can impact performance, drivability, or reliability. Getting ahead of this ensures your vehicle continues to operate as intended. If updates are needed, we’ll guide you through the next steps before you push the vehicle.

If something doesn’t feel quite right, stop driving aggressively and reach out to our team so we can take a closer look. 📋 Letting us know what you’re experiencing—along with any recent changes or conditions—helps us determine next steps quickly. 📈 In many cases, we may request a data log to review what’s happening. ⚠️ Including full DTC reports or relevant screenshots, photos or videos with your request is helpful to us and can reduce the time required for troubleshooting. ⚙️ For transmission-related concerns (e.g., harsh or inconsistent shifting), please see this FAQ: Why is my transmission shifting harsh after tuning? 📌 Please keep in mind: • Tuning can’t resolve underlying mechanical issues • Not all mechanical issues will show clearly in data logs • Overall vehicle condition plays a direct role in performance We’re here to help—reach out and we’ll work with you to get things sorted.

Harsh or inconsistent shifting immediately after a tune is not uncommon and is typically not a concern. Modern Ford transmissions use adaptive learning, meaning the transmission adjusts shift behavior based on driving habits over time. What to expect: Adaptive learning is reset any time the ECU is flashed Initial driving may feel inconsistent or harsh while the system re-learns Heavy throttle / WOT-focused driving early on can delay smooth behavior Adaptation is drive-mode specific, so behavior may vary between modes This relearning process can take several drive cycles depending on driving conditions In most cases, normal mixed driving will resolve shifting behavior as the transmission relearns. ⚠️ When to take action If concerns persist after adequate driving/adaptation, or if you have immediate concerns, follow this process: ✅ Check transmission fluid level ✅ Perform a re-learn cycle ✅ Capture a data log of the concern ✅ Flash back to stock to isolate behavior (if needed) 📎 Transmission Guide (PDF) includes full step-by-step instructions: Fluid level verification Re-learn procedure Logging + next steps 🧠 Important reminders Tuning cannot fix mechanical issues Some mechanical issues may not appear in logs Transmission behavior is heavily influenced by adaptive learning

To ensure your vehicle performs as intended, it’s important to consistently run the specific fuel type your tune was designed for. The fuel type of your tune is in the file name and can be reviewed in the TDN App at any time. Using lower-octane or inconsistent fuel can impact performance, drivability, and overall reliability. If you’re considering changing fuel types (e.g., switching octanes or moving to an ethanol blend), you can purchase an Additional Tune to cover it. Don't hesitate to reach out first so we can confirm compatibility or advise on next steps. 💡 For more information on Fuel and Ethanol Blends, please see the Fuel & Gains section of our FAQ.

2025+ 3.0L Explorer ST/Aviator Kooks GREEN Catted Downpipes

Vehicle Applications

WARNING

Why We Recommend This Product

What should I expect after purchasing?

What should I do to prepare for tuning?

What mechanical checks do you recommend?

How should I prepare for data logging & tune revisions?

What maintenance should I follow after getting tuned?

What should I do before making hardware changes?

What if something feels off?

Why is my transmission shifting harsh after tuning?

What fuel should I run with my tune?

Related Products

Subscribe for updates & promotions

Preferred Contact Method:
email sales@tunedbyzfgracing.com

2025+ 3.0L Explorer ST/Aviator Kooks GREEN Catted Downpipes

Vehicle Applications

WARNING

Why We Recommend This Product

What should I expect after purchasing?

What should I do to prepare for tuning?

What mechanical checks do you recommend?

How should I prepare for data logging & tune revisions?

What maintenance should I follow after getting tuned?

What should I do before making hardware changes?

What if something feels off?

Why is my transmission shifting harsh after tuning?

What fuel should I run with my tune?

Related Products

Subscribe for updates & promotions

Preferred Contact Method: email sales@tunedbyzfgracing.com

Preferred Contact Method:
email sales@tunedbyzfgracing.com