2008-2010 Ford 6.4L Powerstroke Exhaust Manifolds

Exhaust manifolds on the 2008-2010 Ford 6.4L Powerstroke

Each bank of the 6.4L has a cast-iron exhaust manifold that collects exhaust from the ports and hands it to the up-pipes, which run up to the 52 mm variable-geometry high-pressure turbo. The up-pipes bolt to the manifolds with a manifold-side torque spec of 18 ft-lb in a cross pattern, and over-tightening distorts the flanges. Towing and active regeneration, which this first DPF-equipped Powerstroke runs to clean its filter, both put the exhaust through repeated heat cycles. Those cycles are what work on the thin manifold flanges and the short studs.

What fails and why

The factory thin-flange manifolds bow and the short factory studs relax, so the gaskets leak at the ports. It builds with towing and regeneration heat cycles. Signs to look for:

• A tick on a cold start that fades as the engine warms up.
• Soot witness marks around the exhaust ports.
• Delayed turbo spool.
• Exhaust odor at idle.

Because the leak starts at the flange and the studs, the upgrade path addresses both of those, not just the gasket between them.

Stock replacement vs. upgrade

The upgrade for this engine is a high-silicon ductile-iron manifold with thicker machined flanges, longer studs and spacers, which is how BD Diesel builds its 6.4L manifolds. Install matters as much as the part: clean the cylinder head surface to bare metal, torque center-out, and re-torque after the first heat cycle. If you're keeping the factory manifolds, the MAHLE gasket set and the XDP bolt kit are the stock-style repair parts.

What we carry

• BD Diesel 1041482 exhaust manifolds and 1041487 exhaust manifold for 2008-2010 Powerstroke.
• XDP XD626 exhaust manifold bolt kit in black phosphate for the 2008-2010 6.4L.
• Mahle MS19312 exhaust manifold gasket set, listed for 2003-2010 6.0L and 6.4L Powerstroke.
• Fabrication pieces: a BD Diesel 1044106 T3-to-T4 exhaust manifold adapter flange and an ATS Diesel 213-045-1000 45 mm wastegate adapter. These are universal parts, not direct replacements for anything on a stock 6.4L, so call before you order one.

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

Fitment notes

The BD manifolds and the XDP bolt kit are listed for 2008-2010 trucks, and the MAHLE gasket set is listed for both the 6.0L and the 6.4L. When you buy a single manifold, check the listing for which side it fits. The up-pipes bolt to these manifolds, so if your up-pipe bellows are cracked or the flanges are distorted, plan the two jobs together. The 6.4L-specific parts here don't fit the 2011-and-later 6.7L; Ford's all-new 2011 Super Duty does not share 2010-and-earlier exhaust parts. Verify by VIN or use the fitment checker.

Frequently asked questions

How do I know my 6.4L exhaust manifolds are leaking?

The common signs are a tick on a cold start that fades as the engine warms, soot witness marks around the ports, slower turbo spool and exhaust smell at idle. The cause is a bowed thin factory flange, relaxed short studs, or both. Checking the ports for soot is the place to start.

Do new 6.4L manifolds need to be re-torqued?

Yes. Clean the cylinder head surface to bare metal, torque center-out, and re-torque after the first heat cycle. That is the install procedure for the BD high-silicon ductile-iron manifolds with their longer studs and spacers.

Can I reuse the factory manifold studs?

The short factory studs relaxing is part of why these manifolds leak in the first place. The BD upgrade uses longer studs with spacers, and the XDP XD626 bolt kit is here if you're keeping the stock castings. Plan on new hardware either way.

Does the MAHLE gasket set fit my truck?

The MAHLE MS19312 set is listed for 2003-2010 6.0L and 6.4L Powerstroke engines, so it covers the 2008-2010 6.4L trucks. Use the fitment checker on the product page to confirm against your VIN.

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.