2008-2010 Ford 6.4L Powerstroke Exhaust Systems

Filter-back exhaust on the 2008-2010 Ford 6.4L Powerstroke

The 6.4L was the first Powerstroke with a diesel particulate filter. Exhaust leaves the turbos through the downpipe, passes through the diesel oxidation catalyst (DOC) and the DPF, and then exits through the tailpipe section. That section behind the filter is the restrictive part, and it is what a DPF-back system replaces. Because the DPF handles most of the sound attenuation, these systems are described by pipe size, 4-inch or 5-inch, rather than by muffler type. The documented compliant full system for this truck is a true 4-inch DPF-back, single or dual tip, and it leaves everything upstream of the DPF as Ford built it.

What fails and why

Exhaust trouble on this truck lives in the aftertreatment, not the tailpipe. During active regeneration the engine post-injects fuel that burns in the DOC to heat the DPF, and a plugged DPF holds the engine at roughly 1,200 to 1,400 F exhaust gas temperature with high back pressure. Ford approved only ultra-low-sulfur diesel and CJ-4 low-ash oil for the 6.4L; other fuels and oils load the DPF with ash that requires manual cleaning. The fix for a clogged DPF is professional cleaning or an OEM-style replacement DPF, DOC and sensors. A new filter-back system sits behind the DPF, so it will not cure a plugged filter. When you do open the system, MAHLE's catalytic converter and pipe gaskets are the parts to have on hand.

Stock replacement vs. upgrade

If your factory tailpipe section is damaged, any of these systems replaces it behind the DPF. If you're upgrading, you're choosing pipe size, layout and line. MBRP builds 4-inch single, 4-inch dual and 5-inch filter-back systems for the 2008-2010 6.4L in its Armor Lite and Armor Plus lines, and each listing spells out the material and finish. The 4-inch size matches the documented system for this truck and lines up with the 4-inch-inlet tips we carry. The 5-inch option is for owners who want a bigger pipe out back.

What we carry

• MBRP Armor Lite 4-inch filter-back systems: S6242AL and S6242P.
• MBRP Armor Lite 4-inch dual filter-back system: S6244AL.
• MBRP Armor Lite 5-inch filter-back systems: S62460AL and S62460PLM.
• MBRP Armor Plus 4-inch filter-back systems: S6242409 and S6242SLM.
• An MBRP universal exhaust adapter.
• Mahle GS33591 catalytic converter gasket and B32255 and B32256 exhaust pipe gaskets for the 2008-2010 6.4L.
• Pacific Performance Engineering 316129508 horizontal 12-tube EGR cooler, a replacement for the cooler that sees exhaust first and usually plugs or cracks.

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

Fitment notes

Filter-back systems are tied to how your truck was built. The 2008-2010 Super Duty came as a Regular Cab, SuperCab or Crew Cab, with a short box or an 8-ft box, on wheelbases from 137 to 172.4 inches, and the F-450 pickup came only as a crew cab with an 8-ft box. Match the system to your cab, bed and wheelbase, and note whether your truck is single or dual rear wheel. These systems are for 2008-2010 only; the 2011 Super Duty was all-new, and 2010-and-earlier exhaust parts do not carry into it. The 6.4L has no DEF system. Verify by VIN or use the fitment checker.

Frequently asked questions

Does a filter-back exhaust keep my DPF?

Yes. A filter-back, or DPF-back, system bolts on behind the filter. The DOC and DPF stay in place and keep doing their job, and only the section behind them changes. That is the documented compliant exhaust upgrade for the 2008-2010 6.4L.

Should I pick a 4-inch or 5-inch system for my 6.4L?

The documented full system for this truck is a true 4-inch, single or dual tip, and MBRP builds 4-inch single and dual systems to match. MBRP also offers 5-inch versions for the 6.4L. Pick the size that fits the look you want and the tips you plan to run; most tips we carry have 4-inch inlets.

Will a new exhaust fix my regeneration problems?

No. The filter-back section sits behind the DPF, so a plugged filter or a failing DPF sensor is still there after the swap. That calls for professional DPF cleaning or an OEM-style replacement DPF, DOC and sensors, plus ultra-low-sulfur diesel and CJ-4 low-ash oil from then on.

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.