Powerstroke Exhaust Upgrades

These products are popular exhaust options for your Powerstroke. However, to see all exhaust options, please select your vehicle application from the top menu and navigate to the appropriate category.

Do you consider yourself a Ford aficionado? Well, maybe not necessarily an aficionado, but an avid supporter at the very least, right? Either way, if you can differentiate a Powerstroke rolling down the highway before you can see it, you're scoring some points, but if you can tell what series of engine it has (7.3L, 6.0L, etc.), consider yourself a pro.

It all started in 1994 with the release of the first Powerstroke, the 7.3L. In regards to the exhaust system, it was "okay." Most of the system is comprised of three inch diameter piping, which many will upgrade to four inch, the real limitation is actually in the downpipe. The factory downpipe looks like someone took a sledgehammer to it. Many will increase the performance of just the stock system by upgrading the downpipe to an aftermarket system while the most popular upgrade is to go with a complete turbo back system that also upgrades the downpipe.

Model year 1999 saw the release of the first SuperDuty model, still featuring the 7.3L engine, just with some upgrades. The exhaust system on these trucks is somewhat similar to that of its predecessor, but without the crushed stock downpipe. As with the earlier models, its beneficial to bump up to a four inch turbo back system to aid in exhaust expulsion for improved performance, fuel economy, and lower EGT's (Exhaust Gas Temperature). Also, you'll gain a sweet sound of the 7.3L that is truly recognizable instead of masking it with the limited diameter and monstrous muffler.

In mid-model year 2003, came the 6.0L Powerstroke. This truck also features a 3" downpipe like the 7.3L's, but upon entering the catalytic converter, which was another addition, the system turns into a 3.5" diameter. Due to the increase in horsepower of the 6.0L, the larger diameter was necessary in order to aid in heat reduction. Here again, many will upgrade to a four inch, and sometimes five inch kit to let that engine breathe. Further, most 6.0L owners have an obsession with the turbo whine out the exhaust which becomes very noticeable with a higher flowing, or even straight pipe system. And we'd have to admit, its pretty hard not to grin when you hear a 6.0L with a nice exhaust kit.

Up next came the 6.4L Powerstroke released in model year 2008. This exhaust is entirely different than its predecessors as it brought about the introduction of a Diesel Particulate Filter, or DPF for short. The DPF is used in controlling emissions output by creating chemical reactions during what is known as regeneration cycles. We won't go into the details of how all that works here, just know that its complicated. Starting at the turbo and working backwards, this system is four inch diameter and immediately forces exhaust through a catalytic converter located in the downpipe. At the base of the downpipe, another catalyst called a Diesel Oxidation Catalyst, or DOC, is inline, followed by the DPF. Leaving the DPF you'll find a chunk of four inch straight pipe that leads into a small muffler immediately before the axle. From there, its pretty standard, four inch over the axle and to the tailpipe. Phew, did you follow all of that?! There are numerous methods to improve upon this system, but the best and most logical method for most is to install a five inch DPF-back system. A five inch, compared to a four inch, will help remove the exhaust as quickly as possible from the numerous catalysts in front of it. You can upgrade to a single outlet or duals to improve upon the sound and definitely the aesthetics, with moderate gains in power.

For the 2011 model years through current, emissions regulations were again tightened down and we saw the introduction of SCR, or Selective Catalyst Reduction system utilizing urea injection on the 6.7L Powerstroke Scorpion engine. Overall, the rest of the exhaust is somewhat similar to that of the earlier 6.4L models, but with this new addition. In terms of making this better, the same principles hold true. A 5" DPF back system will be your best friend to extract every bit of power, fuel economy, and sound out of your mighty Powerstroke.

Overall, there's an exhausting amount of options when it comes to upgrading the exhaust on your Powerstroke (did you notice the pun!). For some, the decision comes down to sound, to others its about the style, and others performance, but for most its a mixture of all the benefits.

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