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Introduction
Installing a 6.4 Powerstroke DPF delete kit is one of the most popular modifications for diesel truck owners looking to improve performance, increase fuel efficiency, and reduce turbo lag. However, this modification requires some precision and the right tools. In this guide, we’ll show you exactly how to install a diesel DPF delete kit for the 2008-2010 Ford 6.4 Powerstroke, helping you enhance your truck’s exhaust system and engine performance.
Step-by-Step Procedure
Step 1: Removal of OEM Exhaust System
Loosen the Flange Connection: Start at the flanged end of the downpipe. Using the appropriate tools (usually a wrench or socket), loosen the flange connection that connects the downpipe to the exhaust system. This separates the exhaust system from the truck’s main components.
Remove Clamps and Sensors: After loosening the flange, you will need to remove all clamps and any sensors connected to the system. This includes sensors around the particulate filter (DPF). Make sure to carefully disconnect any wiring and set the sensors aside, as they may be reused in the installation.
Detach Metal Hangers: Next, detach the metal hangers holding the OE exhaust system in place. Use a wrench to remove the bolts securing the hangers to the truck's frame or body. You may need to apply some force to remove stubborn hangers, but be cautious not to damage them, as these hangers will be reused later.
Remove Tailpipe Section: If you’re not cutting the tailpipe, removing the tailpipe section is easier when the rear wheels are hanging freely. This can help give you more room to maneuver the exhaust parts during removal.
Remove the Entire OEM Exhaust System: Once all the components are loosened and disconnected, carefully remove the entire OEM exhaust system from the truck. Make sure to store the parts safely in case you need to reuse any elements in the future.
Step 2: Install New Pipe with Flange
Position the New Pipe: Start by positioning the new race pipe (with flange) into place. Insert the welded metal hanger into the OE rubber hanger, which will hold the new pipe in position.
Loosely Tighten Flange Connection: Loosely tighten the flange connection to secure the pipe temporarily. Do not over-tighten at this stage, as this will allow you to make adjustments later to ensure proper alignment.
Install Extension Pipe: Depending on your truck's wheelbase, you may need to install extension pipes to ensure the exhaust system reaches the proper length. The part numbers for the extension pipes will depend on your specific setup.
Reconnect and Adjust: Ensure that the sensor wiring and other lines that were removed from the original exhaust system are reconnected as necessary. Use zip ties to secure any loose wires to the frame to prevent them from interfering with the exhaust pipes.
Step 3: Install Muffler Replacement Pipe
Attach Muffler Replacement Pipe: Now, take the muffler replacement pipe and slide the supplied clamp hanger over the inlet of the muffler. Position the pipe into the OE rubber hanger, securing it in place.
Check Alignment: Ensure that the muffler replacement pipe is aligned properly with the rest of the exhaust system. You should check that there is no excessive bending or twisting in the pipes, as this can affect the exhaust flow and performance.
Step 4: Install Tailpipes
Position the Tailpipe: With the muffler replacement pipe in place, take the tailpipe section and position it correctly. Slide the metal hangers into the OE rubber hangers that you previously detached from the OEM system.
Install Clamps: Place clamps on all the connections, but do not tighten them just yet. You’ll need to make final adjustments in the next steps to ensure everything is aligned properly.
Step 5: Adjust System for Clearance and Tighten Connections
Check Alignment: With all pipes loosely connected, step back and check the overall alignment of the exhaust system. Ensure there is enough clearance between the exhaust pipes and the truck’s undercarriage, suspension, and other parts. This will prevent heat damage or unnecessary rubbing during operation.
Tighten Clamps: Once the system is in place and aligned, begin tightening the clamps. Start at the front flange connection, working your way back to the tailpipe. Use a torque wrench to tighten the clamps according to manufacturer specifications.
Step 6: Install Front Pipe (#21958)
Position the Front Pipe: Slide pipe #21958 over the crossmembers and connect it to the downpipe using the factory clamp and gasket. Make sure that the hanger is securely positioned in the rubber isolator, keeping the pipe in place during the installation process.
Snug the Connection: Tighten the connection enough to hold the pipe in place but allow some adjustment. The pipe should be secure, but not over-tightened, to facilitate any necessary final adjustments later.
Step 7: Install Intermediate Pipe (#31842)
Position the Intermediate Pipe: Install pipe #31842 by sliding the hanger into the factory rubber isolator. Once this is done, connect the pipe to the downpipe. The overlap between the downpipe and the intermediate pipe should be approximately 1.25 inches.
Secure the Connection: Place the clamp on the expansion edge and tighten it to secure the connection. Make sure the intermediate pipe is aligned with the rest of the system.
Step 8: Install Pipe #31515
Position and Install Pipe #31515: Install pipe #31515 into the hangers on the frame. Depending on your truck model, you may have one or two hangers that need to be attached. Ensure that the pipe is securely mounted in the frame hangers.
Measure for Extension: With pipe #31515 in place, measure the gap between it and pipe #31842 to determine if any extension pipe is required. If necessary, trim extension pipe #40020 for a perfect fit. Be sure to allow for sufficient overlap at each end before trimming.
Step 9: Install Muffler and Tailpipe
Install the Muffler: Place the muffler in the correct position, supporting it with a stand to keep it stable while you complete the installation. Adjust it as needed to ensure proper alignment.
Attach Tailpipe #31517: Carefully fit tailpipe #31517 from the rear over the axle. Both hangers should be inserted at the same time as the muffler. It may require some force to manipulate the muffler and tailpipe into place. In some cases, adjusting the spare tire heat shield can provide extra clearance.
Final Alignment: Check the overall alignment of the system once the tailpipe is in position. Adjust it as needed before tightening the connections.
Step 10: Final System Tightening
Tighten All Connections: Starting from the turbo, tighten all bolts and clamped connections. Ensure each connection is secure to avoid any exhaust leaks. Double-check all clamps and bolts to make sure everything is properly fastened.
Conclusion
Congratulations! You’ve successfully installed the 2008-2010 Ford 6.4 Powerstroke Cat & DPF Delete Race Pipe. This modification should improve your truck’s overall performance by reducing turbo lag, enhancing exhaust flow, and increasing fuel efficiency. Be sure to conduct a final inspection to ensure there are no leaks, and test the truck to confirm that everything is functioning correctly.
Final Thoughts:
Remember, removing the DPF system may violate local emissions laws. Always check your region’s regulations before performing this installation to ensure compliance.
