The Ford 6.7L Power Stroke® diesel platform is known as a beast and has been known to produce some serious horsepower and torque, making Super Duty® trucks a beast for hauling heavy loads and working in tough situations. Under certain duty cycles—short trips, heavy idling and frequent regen cycles—the factory emissions system can develop DPF clogging, EGR carbon buildup and DEF crystallization, which lead to significant loss of power, poor fuel economy and unexpected limp modes that can leave a driver in a dead spot.

Some owners and fleet operators therefore choose to remove the emissions hardware. This guide covers the essential hardware changes and the matching software calibration for those considering this transformation. It is intended for off-road, race or other lawful use only. Removing emissions equipment from a road vehicle is illegal and can result in fines, lawsuits, business asset seizures or liens. It can also void warranties and affect insurance claims.

Once the factory system is confirmed unrepairable or a replacement is decided on, the first step in a complete Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) canister replacement is to replace the factory system with a straight-through pipe system. Material selection is very important; mandrel-bent tubing in high-durability T304 or T409 stainless steel ensures the flow of exhaust gases at the highest level even under extreme exhaust gas temperatures.

T304 offers better heat and corrosion resistance for long-term heavy-duty use, while T409 is a lower-cost option with somewhat lower heat resistance. Fitment choices include OE-style bracket mounting, flange precision, and full turbo-back exhaust systems as well as mid-pipe delete parts; these are two distinct approaches, full-system replacement versus mid-pipe replacement and should be selected according to the condition of the factory system and the intended use.

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