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Call or Text (352) 722-5295Exhaust on the 2015-2016 Ford 6.7L Powerstroke
The 6.7L Powerstroke uses reverse-flow cylinder heads, so the exhaust ports face inward and the cast-iron manifolds sit in the engine valley, feeding the turbo almost directly. There are no long up-pipes wrapped around the engine like on the 6.0L and 6.4L. From the turbo, a downpipe carries exhaust to the diesel oxidation catalyst (DOC), the silicon-carbide diesel particulate filter (DPF) and the SCR catalyst, where diesel exhaust fluid is dosed. A single tailpipe exits behind all of that, and Ford built the major exhaust components in stainless steel.
For 2015 Ford replaced the 2011-2014 DualBoost turbo with a larger Garrett GT3788V variable-geometry turbo and added a new exhaust temperature sensor so the engine could run at its 860 lb-ft rating. That turbo has no wastegate, and its hydraulically moved vanes also provide engine exhaust braking. The DPF cleans itself passively above 572 F and actively, with post-injected fuel, above 1,000 F. Ford also made operator-commanded regeneration standard on the diesel, so you can start a regen yourself.
What fails and why
The best-documented exhaust trouble on these trucks comes from how they are driven. An active regen generally needs 10 to 20 miles above 35 mph to finish. A truck that lives in stop-and-go traffic keeps starting regens it never completes, so the DPF stays loaded with soot and fuel from post-injection dilutes the oil. The signs are frequent regen messages, reduced power and an oil level that climbs between changes.
The second pattern starts upstream of the exhaust. A failed boost tube makes the engine run rich, and that can plug the DPF with soot in as little as 5 to 10 miles. Limp mode or a DPF-full warning right after a boost leak is often an intake problem showing up in the aftertreatment, so fix the leak before you chase exhaust parts. One more to know: recall 15V175 covered certain 2011-2015 F-350, F-450 and F-550 trucks with emergency-service packages, where the engine management could falsely detect excess heat and shut the engine down. The fix was a PCM software update.
Stock replacement vs. upgrade
For repairs, stay with OEM-style parts. Replacement EGT and NOx sensors built to the factory design are the correct repair parts on 2011-2016 trucks, along with matching gaskets and hardware. For an upgrade, the compliant path is a DPF-back exhaust, also sold as filter-back, that replaces only the pipe behind the SCR catalyst and keeps the DOC, DPF and SCR in place. That is where you change tailpipe diameter, add a muffler or resonator, or pick a different tip. Manifolds, up-pipes, downpipes and their gaskets and hardware cover the hot side between the heads and the DOC.
What we carry
MBRP supplies most of this page: Armor Lite and Armor Plus filter-back systems in 4-in and 5-in for 2011-2016 trucks, 4-in and 5-in mufflers, Quiet Tone mufflers, resonators, an Armor Lite / Pro 4-in downpipe, a universal exhaust adapter and a long run of tips with 4-in inlets and 4-in to 8-in outlets. The rest of the lineup:
- MAHLE manifold, up-pipe, tailpipe and EGR gaskets, plus 2.5-in and 3.5-in downpipe V-band clamps
- SPE Motorsport exhaust manifolds, machined manifold flanges, a two-piece downpipe, a driver-side up-pipe and EGT sensor adapters
- BD Diesel left, right and paired exhaust manifolds, a V-band clamp and a remote-mount exhaust brake
- PPE high-flow up-pipes and stainless exhaust tips
- Alliant Power NOx sensor module and exhaust back pressure sensors
- Dorman exhaust manifold hardware kits and an EGR cooler gasket kit
- Mishimoto exhaust heat wrap and a 6-in polished tip
- No Limit Fabrication stainless steel downpipe for 2015-2019 trucks
- XDP XD1033 EGT sensor for 2011-2016 6.7L trucks
- ATS Diesel Performance 45 mm wastegate adapter for custom turbo setups
Shopping for more than one truck? Our main exhaust section covers every platform we support.
Fitment notes
The 2015 turbo change is the big split. MBRP lists separate downpipes for 2011-2014 (FS9CA459) and 2015-2016 (FS9CA460), and the pickup part excludes cab-and-chassis trucks. PPE does the same with up-pipes: 316119515 fits 2015-2016 pickups, while 316119511 covers 2011-2014 pickups and 2011-2016 cab-and-chassis trucks. Chassis cabs run a different turbo, so pickup exhaust parts do not carry over to them. Tailpipe routing and length change with cab, bed and wheelbase, and DRW and F-450 trucks differ from SRW. Tips and mufflers are universal and sized by inlet, so read the year range or size in every product title and verify by VIN.
Frequently asked questions
Which exhaust upgrades keep a 2015-2016 F-250 or F-350 compliant?
A DPF-back, or filter-back, system that starts behind the SCR catalyst and leaves the DOC, DPF and SCR in place is the compliant tailpipe upgrade on this truck. The MBRP Armor Lite and Armor Plus filter-back systems on this page are that type. For repairs, OEM-style EGT and NOx sensors are the right parts, and a CARB EO number on a listing proves an aftermarket part is legal in all 50 states.
Why does my 6.7L run so many regens?
An active regen generally needs 10 to 20 miles above 35 mph to finish. Stop-and-go driving keeps interrupting it, so the DPF stays loaded and the truck keeps trying again while post-injected fuel thins the oil. If regens suddenly pile up after a boost tube problem, the rich running from the leak may have loaded the DPF, so fix the leak first.
Will a 2011-2014 downpipe or up-pipe fit my 2015 truck?
Not as a rule. The 2015 turbo change led MBRP and PPE to publish separate part numbers before and after it, such as MBRP FS9CA460 and PPE 316119515 for 2015-2016 pickups. Some parts, like SPE's two-piece downpipe, are listed across 2011-2019, so go by the year range in the product title.
Does the 2015-2016 6.7L have a factory exhaust brake?
Yes. The GT3788V variable-geometry turbo uses a hydraulic actuator to move its turbine vanes, and that setup provides engine exhaust braking. BD Diesel's remote-mount exhaust brake is also listed here; check its product page for application details before you order.
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.