2008-2010 Ford 6.4L Powerstroke Exhaust Accessories

Exhaust accessories on the 2008-2010 Ford 6.4L Powerstroke

The accessory side of a 6.4L exhaust splits into two jobs. Behind the DPF it is tips, clamps, gaskets and hardware for the tailpipe section. Ahead of the DPF it is the gaskets, seals and stud kits that go back in when you do manifold, up-pipe or EGR work. This was the first Powerstroke with a DPF, and its emissions equipment includes exhaust gas temperature sensors and a DPF pressure sensor working alongside the diesel oxidation catalyst (DOC) and the filter. The EGR system runs two coolers in series, a horizontal cooler first and a vertical cooler second, and each one takes its own gasket.

What fails and why

The DPF, its sensors and the DOC are the aftertreatment weak points on this engine. During active regeneration the engine post-injects fuel that burns in the DOC to heat the filter, and a plugged DPF holds exhaust gas temperature at roughly 1,200 to 1,400 F with high back pressure. On the EGR side, the horizontal cooler sees exhaust first and is the one that usually plugs or cracks; MAHLE's horizontal cooler gasket and mounting set are here for that job. Upstream, the manifold flanges bow and the short factory studs relax, so the gaskets leak at the ports. Read the codes and look before you order a sensor or a gasket.

Stock replacement vs. upgrade

Sensors, gaskets and O-rings are service parts. You want the correct part for your year, not an upgrade, and the Alliant Power, MAHLE and XDP pieces here are listed by part number for the 6.4L. Tips and heat wrap are where you get choices. MBRP tips come in rolled-edge, single-wall, dual-wall, angle-cut, straight-cut, turndown and black hex styles, most with 4-inch inlets and outlets from 4 to 8 inches. PPE offers a 3-inch stainless tip and a 4-inch 304 stainless tip, and Mishimoto adds a 6-inch polished angled tip with a rolled edge. If you're keeping the factory exhaust, the MBRP T5111 cover set is listed for the stock 5-inch tip on 2008-2025 Powerstroke trucks.

What we carry

• Alliant Power: AP63473 DPF pressure sensor, AP63423 exhaust back pressure sensor and AP63520 back pressure tube, AP63470 and AP63471 EGR inlet and outlet temperature sensors, and the AP0042 EGR valve O-ring.
• XDP: XD1031 and XD1032 exhaust gas temperature sensors and the XD1035 exhaust back pressure sensor.
• Mahle: G32750 horizontal and G32751 vertical EGR cooler gaskets, the GS33768 EGR cooler mounting set, the G32614 EGR valve O-ring, the GS33591 catalytic converter gasket, and B32255 and B32256 exhaust pipe gaskets.
• Pacific Performance Engineering: the 316129508 horizontal 12-tube EGR cooler, the 316160000 EGR valve gasket and O-ring set, and stainless tips.
• MBRP: exhaust tips in a wide range of styles and the T5111 factory tip cover set.
• Mishimoto: the MMTW-235 exhaust heat wrap set and a 6-inch polished tip.
• BD Diesel: a remote-mount exhaust brake.

Options for every truck are under exhaust, and the rest of the engine is under Powerstroke parts.

Fitment notes

Read the year range on every sensor. The XDP XD1035 back pressure sensor is listed for 2008 only, while the Alliant Power sensors are listed for 2008-2010. Horizontal and vertical EGR cooler gaskets are different parts, so order for the cooler you're opening. Tips have to match your tailpipe size. A few items here are universal or listed for a wider range of trucks, so check each listing against your year, engine and transmission. The 6.4L has no DEF system, so there are no DEF sensors on this page. Verify by VIN or use the fitment checker.

Frequently asked questions

Which EGR cooler gasket fits my 6.4L?

It depends on which cooler you're servicing. The 6.4L runs a horizontal EGR cooler that sees exhaust first and a vertical cooler after it. MAHLE sells the G32750 for the horizontal cooler and the G32751 for the vertical, plus the GS33768 mounting set. If the horizontal cooler itself has to be replaced, the PPE 316129508 12-tube cooler is in this collection.

What's the difference between the DPF pressure sensor and the back pressure sensor?

They are separate parts. The DPF pressure sensor (Alliant Power AP63473) is tied to the particulate filter, while the exhaust back pressure sensor (Alliant Power AP63423, or XDP XD1035 on 2008 trucks) reads exhaust back pressure through its own tube, the AP63520. Let the trouble code tell you which one you need.

Will these tips fit my 6.4L?

Most MBRP tips here have a 4-inch inlet, which suits a 4-inch tailpipe such as MBRP's 4-inch filter-back systems for this truck. If you run a 5-inch system, check the inlet size on the listing first. If you're keeping the factory exhaust, the MBRP T5111 cover set is made for the stock 5-inch tip.

Not sure what fits? Call the shop at the number in the header, or use the fitment checker on any product page. We install everything we sell.