I've had my flow 40 for about 4 months now and at first it was a little loud but then it quietined down alot and sounded good.
Well last week on the way back from a hunting trip it went from sounding nice to loud as hell with a ty tone to it.
I crawled under and looked to make sure it didn't have a hole in it and it doesn't
I've drivin it around as long as I can stand it hoping it would go back to how it was.
So now, I think I'm going to go with a 18" magnaflow with a dump but I might keep the pipe, don't know for sure yet.
I'm going to clamp it until I can borrow my buddys welder but the only question I have is, do I need 2.25" in/outler or a 2.5" to slide it over and clamp it?

 

to limit air flow restriction i would take the the 2.5" od pipe and expand it by .2" for about 3-6", then clamp it, should be the best temporary. if you're short on tools go to meineke and ask for a spare piece of tubing expanded, more than likely they'll do it for free (maybe a 5 or 10 under the table)

 

2.25 in 2.25 out....i really like my magnaflow 18" but maybe i may go with the 24". I dont care to much about sound since anything we add to our trucks sounds like bees in a can.

 

just FYI mags aren't as burly as the flows... call flow and be like hey WTF!?

 

Dude go with the Magnaflow 2.5 in/out. Sounds great after a couple of weeks of driving

 

Quite a few people are running the VORTEX from Jason Burtman, me included. I had a Flowmaster 40 as well and I can say the Vortex is much better. Here is my write-up: clips... comparison view. The clips don't do it enough justice, in person, it sounds amazing! 2.5" inlet, 2.5" outlet on the muffler. Jason offers a single in dual out as well.

 

The VORTEX sounds like anything but that if you ask me.