Up-Pipe Replacement on 6.4 - Pics included - Ford Powerstroke Diesel Forum
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Old 05-01-2014, 08:21 AM

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Up-Pipe Replacement on 6.4 - Pics included

I have been putting this off for almost 2 years, but finally bit the bullet and got this job done. If you read some of my past posts you will see that I have mentioned that I ultimately needed to get this job done. But I will provide a little history because I haven't posted here in a while:

Autumn of 2012 - I started noticing a loud screaming in the engine upon acceleration. When ever the truck would go into regen mode a black billowing of smoke would emit from under the hood, primarily on the passenger side coming up from the wheel well. I determined that my passenger side up pipe had a leak (most likely at the flex bellow where they all crack).

Feb- March of 2013 - Not wanting to spend the money to get pipe replaced (it's a big number as cab needs to come off or drop trans to do the job) I decided I would first spend a little money to delete the DPF on my own. At least this way I could do away with the black smoke during regens. I straight piped from the down pipe back to the muffler, thereby doing away with the Cat and the DPF. The delete tune I installed was the GearBox Z DPF-R + with Economy Tune.

Summer 2013 - Decided to do a full EGR cooler delete as well. I went with the Flo-Pro delete kit with the intake elbow doing away with both coolers as well as the restrictive EGR valve assembly. Now she could breathe!

Truck continued to run well except for the still cracked up pipe, which was probably getting worse. That pipe is right behind the firewall, so the fumes would just come into the cab of the truck, stinking it up, not to mention dangerous to inhale. I would constantly have to use the recirculate button or drive with windows down.

I finally decided to get it to the shop last week. I was very nervous about a cab off job but these guys were super experienced in Powerstrokes. They were very comfortable removing cabs on these 6.4's. I am very happy I finally got this job done. I never thought I was losing a lot of power to the turbos because the truck always felt strong. Just loud. But man was I wrong. If I thought it was powerful before, it's an outright beast now. That sucker jumps with a touch of the accelerator. And the turbos spool right up so quick it blows my mind. Not to mention, she now purrs. It was so loud with the leak, I could barely hear the radio. Now it is completely quiet in the cab. And no more toxic fumes coming in. It's like I got a new truck!

First a few of the cab off:

By the time I got there he already had the old pipes removed. You can see the black soot where the leak was:

Old pipes removed:

New Pipes installed. Note how he welded a plate on the passenger side where the EGR provision pipe would have branched off to feed the EGR system. There was no need for that anymore as I had already removed the EGR coolers. This is a much cleaner look and cleans up that whole mess:

To give you an idea, here are some stock photos of how the original set up would have looked with the EGR provision pipe:

And finally a few shots of how he re routed the EBP sensors. First one he tapped right into the exhaust manifold (this originally would have been in the EGR provision pipe). See what I meant about these guys doing top notch clean work?

and the the Passenger side sensor which is basically in the same place it was on old pipe:

Last edited by mikemass; 05-15-2014 at 03:29 AM.
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Old 05-05-2014, 06:40 PM
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Great pic`s and info . Thanks
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Old 05-20-2014, 03:33 AM
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Great pics, i just bought a 6.4. Why do the up pipes seem to be doubled on these trucks?
Like theres two up pipes per side. Comparing this to a 7.3 when i replaced those up pipes.
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Old 05-20-2014, 03:55 AM

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Compare the pics I posted of mine vs the pics of the stock engine. They really are not doubled up per se. You will see on my truck that I only have 2 pipes. The flow of exhaust gas is coming from each exhaust manifold on lower part of the engine "up" thorough the pipes and into the turbos. That is what provide the tremendous boost to the duel turbo system.

Now look at the stock photos. The same two main up-pipes are still there in the same configuration. However, the difference is the right (passenger side) pipe has a protrusion that comes off the side. About 30% of that flow gets diverted... travels up and over where the other 2 pipes meet the turbo. Fumes travels trough a restrictive catalytic converter on top and then "down" over the left side into that extra pipe which feeds the EGR coolers. I no longer have the EGR coolers, so there is no need for the far left side pipe. Most guys with a delete will just block off that EGR feeder pipe.... Either at the bottom of the pipe where it would have attached to the EGR cooler, or they remove the pipe and block off just to the left of the Cat Converter. I cleaned the whole thing up by getting rid of the whole pipe, the cat and the protrusion and had the passenger side up-pipe welded shut where the protrusion would have been. Hope that explains it and answers your question.
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