The EGR system on a 6.7 Powerstroke may lead to expensive problems, including cooler failures and carbon build-up. Because of this, many drivers consider an EGR delete.
But is this the right move for your Ford F250 F350 F450 F550 truck? To see if EGR kits are worthwhile, you will need to assess the Powerstroke EGR delete pros and cons.
An EGR delete for Ford 6.7 removes the exhaust gas recirculation system from your 6.7L Powerstroke. It boosts power by 5-15 horsepower. You gain better fuel economy, up to 2-3 MPG. It cuts maintenance costs too. But it raises NOx emissions and risks fines.
In this article, we outline the 6.7 Powerstroke EGR delete pros and cons every owner should be aware of. Keep reading.
Table of Contents
- What is an EGR Delete for a 6.7L Powerstroke?
- Pros of 6.7L Powerstroke EGR Delete – Performance & Reliability
- Cons & Risks of EGR Delete for 6.7L Powerstroke
- Legal Alternatives to Full EGR Delete
- Common Signs of a Failing EGR System
- Best 6.7 Powerstroke EGR Delete Kit
- FAQs
- Conclusion: Is the 6.7 Powerstroke EGR Delete Right for You?
What is an EGR Delete for a 6.7L Powerstroke?
A Ford 6.7 EGR delete removes the EGR valve and cooler from your 6.7L Powerstroke. It stops exhaust gas from mixing with intake air. This change improves airflow. Your engine runs cooler and stronger.
The 6.7L Powerstroke diesel engine employs an Exhaust Gas Recirculation (EGR) system for emission reduction by sending some of the exhaust back to be mixed with fresh charge air in the intake system.
This will reduce the level of nitrogen oxides (NOx) emitted from the engine; however, it also returns hot exhaust, which is very high in soot, back to the engine, leading to clogged intake systems, carbon buildup, and EGR cooler failures.
A 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019 F250 F350 EGR delete is the process of removing or bypassing this system. The EGR delete kits for the 6.7 Powerstroke diesel engine have performance valves that allow the exhaust gases to stop flowing back into the intake system.
The engine will use fresh, cooler air instead, which provides for better combustion and performance.
How It Works
When installed, a 6.7 Ford EGR delete kit will block off or remove the EGR valve and cooler. Most kits come complete with block-off plates, coolant line reroute(s), and possibly tuning software.
After the delete is completed, the engine no longer recirculates exhaust gases. The entire idea behind the 6.7 Powerstroke EGR delete is to reduce common failure points and improve reliability.
Many truck owners also pair the delete with tuning to modify fuel delivery, vehicle timing, and exhaust gas temperatures (EGTs). This can lead to increased horsepower, improved throttle response, and extended turbo life.
In short, an EGR delete for 6.7 Powerstroke replaces an emissions system with a performance-focused setup. While this may seem beneficial, there are some risks that we will discuss the EGR removal pros and cons in the following sections.
Pros of 6.7L Powerstroke EGR Delete – Performance & Reliability
Deleting the EGR system on a 6.7L Powerstroke can provide multiple benefits for performance, reliability, and long-term maintenance.
EGR delete stops cooler failures. It cuts carbon buildup. You get better fuel use. Power jumps 5-15 HP. Maintenance drops. Turbo lasts longer. Kits install easy.
The key benefits are listed below, with real-world data to back up the claims.
1. Removes EGR Cooler Failure
The EGR cooler is one of the most common points of failure on the 6.7 Powerstroke. In a study, 43% of 6.7L engines developed cooler leaks by 100,000 miles (PowerStrokeTechs, 2025).
An EGR delete for 6.7 Powerstroke eliminates this weak point of failure and can save you from the expenses of a breakdown.
2. Reduces Carbon Buildup and Clogging
The EGR system pushes soot back into the intake, coating the valves and manifolds in carbon. Deleting the EGR on Ford 6.7 Powerstroke can exclude as much as 72% of what would be ingested into the intake system (Diesel Power Project).
This leads to better airflow and flow characteristics, requires less maintenance, and creates more horsepower.
3. Increases Fuel Efficiency
With cleaner combustion and lower exhaust gas temperatures (EGTs), better fuel economy is achieved. Many drivers report increasing their fuel efficiency from 15 MPG to 17-18 MPG simply by performing an EGR delete and tune.
EGTs can be as much as 150°F lower at heavy loads, after removing the EGR, creating additional engine safety.
4. Increases Horsepower and Torque
How much horsepower does a deleted 6.7 Powerstroke have? By removing restrictions and improving airflow, deletes typically add 5–15 hp. Also, when paired with a tune, many drivers note a quicker throttle response and improved towing power.
5. Reduces Maintenance Expenses
Repairs done on EGR systems cost $500 - $2,000. When you delete your system, you will no longer have to worry about repeated cooler expenses, cleaning clogged valves, or diagnosing EGR issues. Even EGR cleaning costs you money, generally $150 every 20,000 miles.
6. Extends the Service Life of Turbochargers
The turbo will not have to deal with hotter, soot-filled gases recirculating back into the intake and will see far less carbon buildup and oil coking. This reduction in wear can help prevent premature turbo failure.
7. Easy Install Kits Readily Available
Most complete delete kits for your 6.7 Powerstroke come with block-off plates, coolant reroute kits, and all hardware needed. With basic tools, the install can be done in a few hours and even less if coupled with a tuner.
Cons & Risks of EGR Delete for 6.7L Powerstroke
Although the advantages of removing the EGR system are appealing, it comes with severe consequences.
Ford 6.7 EGR delete breaks emissions rules. It voids warranty. NOx rises. Turbo may surge. EGTs climb. Knocking happens. Costs start high. Resale drops.
From emissions compliance to warranty issues, here are the main risks to be aware of.
1. Emissions Compliance Issues
The greatest negative impact of an EGR deletion is your Ford F250 F350 F450 F550 truck's failure to comply with emissions laws. In many states, a deleted truck will fail inspection.
Statistics from the EPA show that in 2025, fines related to deletions increased by 127% (SEMA Report).
States like California, New York, and Pennsylvania automatically fail trucks modified by missing or disabled EGR systems. This means you risk getting tickets or fines, and worse, you may not be able to operate your Ford F250 F350 truck legally on public roads.
2. Warranty Voidance
Ford dealerships utilize advanced diagnostic tools, including FDRS scans, that document vehicle history and will be able to identify any tunes on your ECM or EGR deletes (SSM 51739).
If they discover any modifications like 6.7 Powerstroke EGR deletion, they can void your powertrain warranty, and you risk losing valuable warranty coverage that can be costly on newer trucks.
3. Increased NOx Emissions
While the overall performance of the Ford truck improves after the delete, it significantly increases nitrogen oxide emissions. Studies from SAE indicate emissions can be up to 5 times that of a stock vehicle in NOx output.
Emissions also contribute to environmental pollution and will result in limited restrictions on areas you can operate a deleted truck.
4. Risk of Turbo Surge
Without proper tuning, a delete for 6.7 Powerstroke can lead the turbocharger to experience a compressor stall or surge. Because the EGR valve is no longer regulating airflow, boost pressure can become unstable and lead to damage.
5. Higher Exhaust Gas Temperatures (EGTs)
A poorly tuned delete can actually result in higher EGTs, which can cause stress on pistons, valves, and head gaskets with continued exposure to high temperatures, which can lead to premature wear or catastrophic failure of the engine. Watch your EGTs.
6. Possible Engine Knocking
Rather than just increased EGTs, some owners reported light knocking or pinging when going under load. While tuning typically solves this issue, if the conditions are not optimal, tuning is not appropriate for the engine, and additional engine strain can occur over time.
7. Costs of Upfront and Tuning
Typical pricing for a 6.7 Powerstroke delete kit ranges from $400-800, and professional tuning adds $500-$1200. The labor costs for installation can also cost a few hundred dollars, and when considering your total investment, can reach over $2000.
8. Less Resale Value
Many potential buyers will not want to purchase a Ford truck that has been deleted and is not compliant with emissions.
Even if they buy a deleted truck, if local/regional laws prohibit emissions-delete vehicles from being registered, then the buyer may lose thousands upon resale value if the delete was performed.
Legal Alternatives to Full EGR Delete
After weighing the EGR delete pros and cons, you many wonder is there any alternative solutions? Not every driver is willing to risk fines, loss of warranty coverage, and a failed inspection by fully deleting their vehicle's EGR system.
Legal options keep compliance. Upgrade coolers. Clean systems. Use limiters.
Fortunately, there are legal options to improve performance and reliability without removing emissions equipment. These options will allow you to keep your truck road-compliant while alleviating many of the common concerns about the factory EGR system.
1. Heavy-Duty EGR Cooler Upgrades
The EGR cooler is one of the most prominent failure points in the 6.7L Powerstroke. The stock cooler commonly fails because of leaks and cracks that form when the truck has around 80,000–100,000 miles.
Instead of deleting the cooler, many truck owners relied on upgraded EGR coolers that are built with higher-quality materials and a redesigned internal passage.
Performance coolers are built to withstand thermal stress, enable better coolant flow, and typically last much longer than stock EGR coolers. This upgrade addresses the main point of failure without an emissions compliance violation.
2. Regular EGR and Intake Cleaning
Carbon buildup in the EGR system is also a primary reason the EGR system becomes clogged and has drivability issues. Over time, soot and ash constrict airflow, which results in less efficiency and horsepower.
Once again, you can schedule a professional cleaning service for both the EGR and intake every 20,000-30,000 miles to keep the system functioning properly.
Relying on professionals costs around $150–200, which is significantly lower than replacing the EGR cooler or valve. There are cleaning sprays and DIY intake cleaners available for less than $50 for those who want to try this themselves.
3. EGR Limiters or Recalibration that are EPA-Compliant
Several aftermarket product developers offer EGR limiters or software recalibrations that can help decrease the aggressiveness of the exhaust gas recirculation systems.
These can help minimize soot buildup, yet keep the Ford truck able to pass emissions testing. While they will not generate the same gains in horsepower or fuel mileage as a full delete, it is a reasonably balanced middle ground.
Although the modifications provide more peace of mind and reliability, they eliminate any concerns related to a full delete risk.
4. Preventive Maintenance and Monitoring Solutions
Even if a truck has not been modified, diligent scheduled maintenance goes a long way. Cleaning the fuel system with quality products in conjunction with running quality diesel fuel, oil changes, and regular filter replacements can all help mitigate soot buildup.
Many truck owners also take it one step further and opt to install exhaust gas temperature gauges or monitoring systems in their trucks to gain operational statistics to monitor exhaust gas temperatures.
By catching when there are exhaust gas temperature issues in the earliest stages possible, it is easier to avoid an expensive failure and extend the life of the EGR system.
5. Factory Similar Tuning Options
Full delete tunes or tuning options in most states are illegal; however, there are some 50-state legal tuners available that enhance fuel outputs, timing, throttle response, and others without entirely shutting off the emissions system.
When under load and while towing, these mild tunes can make for a noticeable improvement in drivability and sheer power generation without breaking EPA laws.
These are palatable middle-of-the-road options for drivers who want the performance of a delete option but want to stay in the range of being able to pass emissions testing.
Common Signs of a Failing EGR System
It's crucial to understand the signs of a failing EGR system before you decide to delete it on your 6.7 Powerstroke. A clogged or faulty EGR valve will typically cause rough idling, poor fuel economy, and loss of power when accelerating.
You may also begin to see black soot in your exhaust, along with an illuminated check engine light, referring to EGR flow problems. Over time, carbon build-up will begin to restrict airflow inside the intake manifold, causing the engine to run hotter and less efficiently.
In the worst-case scenario, if the EGR cooler has a coolant leak, it can get into the exhaust, causing white smoke, overheating, and possibly a blown head gasket.
Many owners also report cold starts and the need to occasionally reset limp mode, which tend to be the first signs that the EGR System is not functioning properly.
Early detection of these issues will help determine whether a repair is needed or a delete is the best way to go for your truck.
Best 6.7 Powerstroke EGR Delete Kit
If you have decided to carry through with a delete, you will want to invest in a good kit for long-lasting peace of mind. One of the best kits you can choose is 6.7 Powerstroke EGR Delete Kit at egrperformance.com.
Constructed of precision machined aluminum alloy, the kit provides all the necessary gaskets and hardware, for a worry-free clean installation too. And with proper tuning, it lowers exhaust gas temperatures, eliminates coolant leaking, and allows for improved throttle response.
EGR Performance kits are designed for perfect OEM fit with the extreme heat and pressure Powerstroke engines produce.
Installation should be conducted by a certified technician, and modification should comply with local regulations. Choosing a premium kit like EGR Performance ensures durability, reliability, and smoother engine performance for years to come.
FAQs
Will EGR delete hurt the engine?
No, the engine will not suffer from an EGR deletion if done and tuned properly. In fact, it may increase reliability by deleting components prone to failure. Poor tuning, however, can increase exhaust gas temperature and cause damage.
Does EGR delete cause the check engine light?
Yes, if you remove the EGR system and are not tuned properly, the check engine light will turn on. If EGR is deleted, you load a tune that will reprogram the ECU and not trigger the error codes.
Do you have to tune a 6.7 after an EGR delete?
Yes, you will need to tune it. If you delete the EGR and do not tune it, the Ford F250 F350 truck will run poorly, trigger the check engine light, and likely have adverse effects on fuel economy.
How long does it take to delete EGR on a 6.7 Powerstroke?
In general, most EGR delete kits for the 6.7 Powerstroke install in about 4-6 hours using basic tools. A shop may do it faster depending on experience.
What maintenance is required after deleting the EGR?
After EGR is deleted, you still need to monitor EGTs (exhaust gas temperatures) and change the oil and fuel filters as required. Since you don't have EGR, maintenance is simpler and less expensive.
How do I monitor exhaust gas temperatures after an EGR delete?
You can monitor the EGTs by either a digital gauge or an aftermarket tuner that has monitoring options available. Keeping the EGTs under control is imperative to avoid any issues with your engine and to avoid damaging the turbo system.
Conclusion: Is the 6.7 Powerstroke EGR Delete Right for You?
Deleting 6.7 powerstroke has pros and cons as mentioned above. 6.7 Powerstroke EGR delete boosts power but risks fines and emissions. It fits off-road use. Stock or upgrades suit daily drives. I chose wisely for my needs.
Whether or not to delete the EGR system ultimately comes down to how and where you are using your Ford F250 F350 F450 F550 truck. If you are experiencing regular EGR failures, frequently towing heavy loads, or using the truck for off-road use, deleting the EGR system will provide added reliability and overall reduced maintenance costs down the road.
However, if your truck is mainly driven on the street and/or subject to emissions laws, deleting the EGR system may expose you to legal trouble and unnecessary warranty issues.
Once you have explored both sides of the 6.7 Powerstroke diesel EGR delete pros and cons, you will be able to make a more informed decision based on your own needs.
About the Author- John Barrett
EGR Performance Writer and a 20-year veteran of the truck industry—whether it's diesel engines, or transmission systems, I've spent decades getting my hands dirty with every part of a truck.
I love tearing down worn components to trace exactly why they fail, and I firmly believe: if a truck part can't be fixed right, it's not worth keeping on the road.
