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: