The EGR and DPF system is poorly designed. The Exhaust Gas Recirculation (EGR) system consists of two EGR coolers and an EGR valve. Exhaust gas enters the lower EGR cooler from the driver’s side exhaust manifold. It then passes through the top EGR cooler. The upper cooler is connected to the EGR valve that will introduce the hot exhaust gas into the intake manifold. The Diesel Particulate Filter (DPF) system is the large round unit located underneath the truck towards the front of the exhaust system. The DPF is the back part of that unit behind the row of bolts that connects it to the catalytic convertor in the front.
The most common modification is that the EGR and DPF system can be removed to make the truck reliable like the 6.0’s. The Sinister EGR Delete with intake elbow will let you remove both EGR cooler and the EGR valve. There are DPF/CAT delete pipes that bolt directly in place of the convertor and filter as well as complete exhaust systems from MBRP, Diamond Eye, AFE, and Flo Pro. If you install either product by itself, the truck will throw check engine codes and may enter a no start fault. A programmer we can install take the DPF and EGR programming from the vehicles ECM. We use such trusted brands as H&S Performance MiniMaxx or XRT Pro. Not only will they allow for the complete removal of the EGR and the DPF but all related sensors, BUT will give you a boost in horsepower.
The 6.4 Power Stroke engine is a simple rail type fuel system. What that means is that there is a central injection pump that pressures the fuel up and delivers it to a rail on each head. Every injector has a single fuel line from the rail to feed it this high pressure fuel. If any fuel leak occurs in this system, it will leak directly into the engine oil. Also the factory fuel system can transfer dirt, trash, and water into the injection pump. Resulting in injectors misfiring, firing erratically, or even being stuck open. When this happens you take a huge chance in cracking a piston, bending a rod, or even a sash out cycle.
What we recommend is the FASS fuel system. It has been proven the best and the most durable for any application and has not been found to reproduce the factory system. A complete custom fit to your Powerstroke, you will be sure that with the FASS Fuel System and Dallas Diesel attention to detail, you will be on the road longer.