6.7 Powerstroke MPG After DPF Delete vs Stock

Fuel economy is a significant concern for many 6.7L Powerstroke owners, particularly with the rising cost of diesel. Many tuning companies promise large gains, but real-world results are more modest. These owners wonder if a DPF delete can fix it.

Typically, a 6.7 Powerstroke with a DPF delete gains approximately 2–4 more MPG on the highway and only a small increase, often 1-2 MPG while towing. Up to 5 MPG gains when empty.

This increase is due primarily to the elimination of regeneration cycles and exhaust restrictions.

I own a 2015 F-350 with the 6.7L. I looked into this mod for years. I read forums and talked to other drivers. This guide focuses on 6.7 Powerstroke MPG real data after DPF delete.

Read on if you want honest numbers on 6.7 Powerstroke fuel mileage improvement, plus the DPF delete risks, costs, and if it is worth the cost for fuel savings.

Real-World Stock vs. Deleted 6.7 Powerstroke MPG

Stock 6.7 Powerstroke trucks frustrate owners with regen cycles. These burn extra fuel. Backpressure hurts efficiency too.

Stock vs Deleted MPG Breakdown

Real-world research has shown a clear, yet reasonable, increase in 6.7 Powerstroke MPG with the removal of the DPF system.

After a DPF delete and proper tune, most owners gain 2-4 MPG on average, not the remarkable increases that are often stated by others.

Stock highway mileage sits at 15-18 MPG. Deleted trucks often hit 18-22 MPG empty. City driving improves less, but combined gains feel solid.

I pulled data from forums like Powerstroke.org and real owner reports. Results vary by year, driving style, and tune. Newer trucks (2020+) start with better stock efficiency. Older ones gain more.

Some tuners claim that they can provide a 30% increase in fuel efficiency. However, in reality, most drivers will obtain approximately a 20% increase in fuel efficiency (3-4 MPGs) in mixed driving.

Driving habits also greatly affect fuel efficiency. For example, an individual who accelerates aggressively will most likely lose their mileage gains after tuning, regardless of whether the DPF has been removed or not.

Average Reported MPG

Condition	Stock MPG	Deleted MPG	Typical Gain
Highway (Empty)	15–18 MPG	18–22 MPG	+3–4 MPG
Mixed Driving	14–16 MPG	16–19 MPG	+2–3 MPG
City	12–15 MPG	14–17 MPG	+1–2 MPG
Towing (10k+ lbs)	9–12 MPG	10–14 MPG	+1–2 MPG

These numbers come from hand-calculated tanks. Lie-o-meters often read high.

Why Gains Vary So Much

Some owners report only 1 MPG improvement. Others hit 5+ MPG.

Key factors include:

• Tune quality: Eco tunes focus on efficiency. Hot tunes add power but can hurt mileage if you drive hard.
• Driving habits: I know one guy who deleted his truck. He gained power and floored it everywhere. His MPG dropped.
• Truck setup: Bigger tires or lifts cut gains. Stock setups see the best jumps.

In my case, I drive mostly highway miles. I expect 3-4 MPG gain if I delete. But I weigh the risks too.

The reality hits home on long trips. Regen cycles waste fuel. One owner said his stock truck dropped 2-3 MPG during regens. After DPF delete, no more waste.

Towing vs. Empty: 6.7 Powerstroke Fuel Mileage Improvement

The largest 6.7 Powerstroke fuel mileage improvement is seen when driving empty on the highway. With much more efficient fuel combustion (due to less exhaust restriction and no regen cycles) through lower RPM, and more direct fuel combustion.

Most owners are reporting approximately 3-5 MPG more fuel economy when driving steadily on the highway after doing a proper delete and tune. This is where deleted setups show significant improvement in real-world use.

When towing heavy loads, gains are far less. Most owners report a gain of only about 1-2 MPG when towing 10,000 lbs or more. The engine will use a fixed amount of fuel to create power while pulling, regardless of how efficiently the fuel is burned. But lower EGTs make long hauls safer on long, steep uphill grades.

Empty Driving Gains

Light load or empty runs shine after delete. No regen interruptions. Reduced backpressure lets the turbo spool better.

Owners report:

• Highway at 70 MPH: Stock 16-17 MPG → Deleted 20-21 MPG.
• Best cases: Careful drivers hit 22+ MPG on flat roads.

I took a stock 2017 F-250 on a trip once. It averaged 17 MPG empty. A similar deleted truck ran the same route at 21 MPG.

Towing Gains

Heavy towing needs fixed fuel for horsepower. Backpressure hurts less here.

Typical reports:

• Towing 10-12k lbs: Stock 10-11 MPG → Deleted 11-13 MPG.
• Gains come from no regens and cooler runs.

Lower EGTs stand out. One forum user towed grades. His stock truck hit high temps. Deleted, EGTs dropped 200°F. Safer for the engine.

Towing MPG Comparison Table

Tow Weight	Stock MPG	Deleted MPG	Gain	Notes
No Trailer	16–18 MPG	19–22 MPG	+3–5 MPG	Biggest improvement
8–10k lbs	11–13 MPG	12–14 MPG	+1–2 MPG	Steady highway
15k+ lbs	8–10 MPG	9–11 MPG	+1 MPG	Mountains cut gains

If you tow a lot, gains pay off over miles. But empty drivers see the real savings.

Why Removing the DPF Can Increase MPG on 6.7 Powerstroke

The DPF traps soot. It needs regens to clean. These burn extra fuel.

Remove the DPF. End regens. Cut backpressure. The engine breathes better. Efficiency rises.

End of Regen Cycles

DPF removal has the potential to increase 6.7 Powerstroke MPG fuel efficiency due to how the DPF functions mechanically, primarily because it eliminates regeneration cycles.

In the stock configuration, your engine regularly injects additional fuel into the system in order to create higher exhaust temperatures to facilitate the burning of soot within the DPF.

The additional fuel used for regenerative processes is a waste of energy, as it doesn't contribute to forward movement. When you remove your DPF from your vehicle's exhaust system, you eliminate any maintenance required for regeneration procedures and conserve on wasted fuel.

Stock trucks regen often in the city or on short trips. Highway less so. Delete stops this. One owner calculated 1-2 MPG loss just from regens.

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Lower Exhaust Backpressure

Reduced exhaust back pressure is an important factor for greater fuel economy. The diesel particulate filter (DPF) adds resistance to the exhaust system as it loads up with soot. This causes the turbocharger and engine to have to work harder to push the exhaust gases out of the system.

After removing the DPF, the exhaust flows freely. Therefore, the turbocharger operates more efficiently, and the engine can maintain speed with less throttle input.

In turn, less fuel is needed. This improves highway MPG on a deleted 6.7-liter Powerstroke engine.

Backpressure Impact Table

Setup	Typical Backpressure	Effect on Efficiency
Stock with DPF	High (5–10 psi+)	Reduces MPG due to exhaust restriction
Deleted	Low (1–2 psi)	Improves exhaust flow and fuel efficiency

Better Combustion

Combustion efficiency improves as a result of a tuned engine. When an exhaust system provides freer flow, it allows an engine to achieve optimal fuel delivery and timing.

Result: Cleaner burn. More power from the same fuel.

Achieving complete combustion allows for smoother power production and improved fuel economy for a 6.7 Powerstroke diesel engine while maintaining constant speed on the highway.

I saw a diagram once. It showed how backpressure builds. Delete drops it fast.

Combined, these give the 2-4 MPG gain most see.

Key Steps for Maximizing MPG on a 6.7 Powerstroke

The delete kit alone helps. But more steps push gains higher.

Get a good tune. Drive easily. Add other mods. Monitor data. Maintain basics.

Get a Proper Tune

When it comes to achieving better 6.7 Powerstroke MPG, the biggest impact will be from a properly tuned engine. Without tuning, a DPF delete provides limited gains.

Eco and tow tunes are adjusted for efficiency, not for maximum power, by adjusting fuel timing, boost levels, and throttle response.

The tune matters most. Eco tunes prioritize mileage. I recommend custom tunes. They fit your truck.

Aggressive or poor tuning can actually cause you to use more fuel than you otherwise would have used, even with a deleted setup. A quality tuner can help you achieve consistent and measurable MPG gains.

Drive Conservatively

Your fuel economy is affected directly by your driving habits.

Extra power tempts hard driving. It kills gains. Keep speeds 65-70 MPH.

Maintaining smooth acceleration over long distances and avoiding "lead foot" driving helps keep your DPF delete fuel savings.

Complementary Deletes

In addition to the DPF delete, making legal complementary deletes where possible (i.e., EGR delete and DEF delete) helps optimise air flow through the exhaust, reduce restrictions on your engine, reduce the amount of heat your engine generates, and produce the most efficient combustion of fuel.

These two modifications, combined with tuning, allow for optimal air flow and optimal combustion and produce the best possible MPG on highways and in cities.

Monitor and Adjust

Keeping a close eye on your MPG, boost pressure, and exhaust gas temperature helps you identify any driving habits or mechanical issues that could be affecting your vehicle's fuel economy.

When you notice an issue with driving habits or mechanical issues, you need to adjust your tuning and driving behaviour to maintain the most efficient use of your fuel over time.

Maintain Tire Pressure & Reduce Weight

Maintaining the correct air pressure in your tires improves the fuel economy of your truck and increases its rolling efficiency. When tire pressure is too low, it's harder for the truck to roll.

Keeping your truck's weight as low as possible, including removing heavy cargo and extra equipment, helps your engine work less and improves the fuel mileage on a 6.7 Powerstroke.

Making even small changes to tire pressure and weight can create significant improvements in fuel economy over longer distances.

MPG Tips Table

Tip	Expected Gain	Notes
Eco Tune	1–2 MPG	Prioritizes fuel efficiency over performance tuning
65 MPH Cruise	2–3 MPG	Compared to cruising at 75+ MPH
Proper Tire Pressure	0.5–1 MPG	Check and maintain pressure monthly
Remove Bed Load	~0.5 MPG	Less weight results in better fuel economy

I follow these on my stock truck. They help a lot.

Factors That Influence 6.7 Powerstroke MPG After a DPF Delete

No two trucks match. The extent of the improvement from a DPF delete depends on many factors. Tune quality leads. Then habits. Set up matters too.

By being aware of these factors, it is possible to have the best fuel efficiency while waiting for the DPF delete to be completed.

Tuning Quality and Power Level

The type of tune used on a vehicle after completing a DPF delete plays a very important role in how much fuel economy increase is possible.

A proper eco-tune, or tow-tune, helps the engine run as efficiently as possible. On the other hand, aggressive, poorly calibrated tunes may actually cause a decrease in fuel economy.

Eco tunes give the best mileage. Performance tunes add fun but less efficiency.

A proper tune ensures the engine performs optimally at all times.

Driving Habits (Towing, Highway, City)

Towing, driving on highways, and driving in cities all have a direct impact on your fuel efficiency.

There is a direct relationship between the amount of cargo you are carrying (towing) and your highway driving efficiency, since light loads provide the best opportunity for maximizing the efficiency of your vehicle (typically an increase in fuel economy of 3–5 MPG).

When it comes to city driving, frequent stopping and starting will reduce the efficiency you gain. Typically, it will only be 1-2 MPG. As a result, if you're a heavy-duty tow truck, you will have a lower potential to increase your fuel economy due to the increased need for fuel to power the engine.

Tire Size, Gear Ratio, and Lift Kits

Big tires drag. Lifts add wind resistance. Stock setup is best for MPG.

Tire size, gear ratio, and lift kits also affect rolling resistance and how much work an engine must do. Massive tires, a higher gear ratio, and lift kits create more stress on the engine and reduce fuel efficiency.

Your stock configuration typically provides the best balance of power and fuel efficiency.

Exhaust Setup

Straight pipe flows best. Muffler quiets but slight restriction.

The design of the vehicle's exhaust system significantly affects how efficiently air flows through the system and how turbochargers perform.

Performance and straight-pipe exhaust systems produce little or no back pressure when compared to stock exhaust systems, which means that they will improve combustion efficiency, which will improve fuel efficiency (i.e., MPG).

A poor exhaust design or exhaust component(s) that cause excessive back pressure (i.e., catalysts, mufflers, or bands) will reduce the amount of fuel savings realized from a DPF delete installation.

Vehicle Load

Extra weight hurts. Empty best.

Hauling heavy loads or pulling trailers adds to the vehicle's weight and, therefore, increases its fuel consumption. All trucks that are used to haul a load consume more fuel than trucks that are empty, regardless of whether or not the vehicle has a DPF delete or is tuned.

Avoiding carrying unnecessary weight and distributing loads in a manner that minimizes additional weight allows for continued benefits from DPF deletes.

Factor Impact Table

Factor	Positive Impact	Negative Impact
Eco Tune	High MPG	-
Highway Driving	Big gains	-
Oversized Tires	-	Reduces 1–3 MPG
Heavy Load	-	Cuts gains in half

I learned this from friends. One added 37s. His gains dropped.

Risks of Improving 6.7 Powerstroke Fuel Economy with a DPF Delete

While a DPF delete can improve 6.7 Powerstroke MPG and fuel economy on a 6.7 Powerstroke, there are significant risks that should be considered by each truck owner before removing the filter.

Legal issues surrounding removal, warranty coverage, and long-term resale value should be considered before modifying the original Ford 6.7 Powerstroke diesel fuel system.

Federal EPA Regulations

Under federal law, it is unlawful to remove the Diesel Particulate Filter (DPF). The Environmental Protection Agency has implemented and tightly enforced emissions regulations with strict penalties for noncompliance.

Vehicles not equipped with DPFs could potentially fail emissions tests in those states that have adopted the federal guidelines. Thereby, limiting fuel mileage 6.7 Powerstroke.

State Inspection Concerns

Numerous states mandate emissions testing on diesel trucks for registration purposes, and many diesel trucks equipped with a 6.7-liter Power Stroke that have the DPF removed may be unable to pass these emission tests, preventing them from being driven legally on public roadways.

Depending on the state in question, a truck owner could face an assortment of consequences, including fines, costs associated with reinstalling the DPF, and noncompliance leading to the denial of registration to operate their 6.7 Power Stroke deleted MPG trucks.

Warranty

Most Ford 6.7 diesel trucks come with a warranty covering drivetrain and exhaust system issues. However, once you install a DPF delete, this will cancel out your vehicle’s warranty.

In case of any future issues with your diesel truck’s engine, turbocharger, or emission-related components, it is likely that the warranty would no longer cover the repairs, leaving the owner responsible for those costs.

Resale Value

Modified trucks with a deleted 6.7 Powerstroke often have lower resale value.

This is because many buyers have concerns about DPF removal legal issues, emissions compliance, and maintaining a vehicle that potentially has more expensive maintenance costs. A better option would be to leave the truck in stock form, which would help preserve the long-term value of the vehicle.

Risk Summary Table

Risk	Severity	Details
Legal Fines	High	Federal violation
Inspection Fail	Medium–High	Depends on state
Warranty Loss	High	Full powertrain void
Resale Drop	Medium	Fewer buyers

I worry most about warranty. My truck still under coverage.

6.7 Powerstroke Delete Cost vs Fuel Savings

You can improve 6.7 Powerstroke fuel mileage with a DPF delete; however, it does require some initial investment.

The DPF delete kit and tune will be your two main costs associated with the DPF delete project, and together they range anywhere from $1,200 - $2,500 for the complete package, depending on the brand of the DPF delete kit and the type of installation (DIY or professional). Savings come over miles.

Delete Kit + Tuning Cost Comparison

• Basic kit: $500-1000. Full exhaust: more.
• Tuner: $900-1600.
• Labor: $300-800 if not DIY.
• Total: $2000-4000 average.

Although a DPF Delete Kit may appear expensive to purchase and tune, you should factor in the potential savings from improved fuel mileage and reduced fuel consumption when evaluating the cost of this upgrade.

Many quality premium delete kits produced by well-known manufacturers like EGR Performance provide improved exhaust flow and reduced backpressure. Conversely, cheap delete kits might create performance problems or reduced fuel economy.

Therefore, when choosing a delete kit, you should choose one from a trusted manufacturer.

Fuel Savings Over 10k–50k Miles

• At 2-4 MPG gain. Diesel $4/gallon.
• 10k miles/year: Save about $400/year.
• 20k miles: $800/year.
• 50k miles: $1,000–$2,000/year
• Payback in 3-5 years.

In real-life situations, a 6.7 Powerstroke that has been deleted can achieve an increase in fuel economy of between 2–4 MPG on the highway, and somewhat lower while driving in the city and/or while pulling a trailer.

If driven over 10,000 miles, fuel costs would be saved by approximately $200–$400, depending on fuel prices. A truck that has driven over 50,000 miles would yield fuel cost savings of $1,000–$2,000 and would nearly pay for the cost of the kit and tuning, assuming the truck is driven primarily on the highway.

Cost vs Savings Example

Risk	Severity	Details
Legal Fines	High	Federal violation
Inspection Fail	Medium–High	Depends on state
Warranty Loss	High	Full powertrain void
Resale Drop	Medium	Fewer buyers

High-mile drivers win fast. I drive 15k miles. It takes time. But long-term worth it.

FAQs

Can a DPF delete hurt fuel economy?

No. A proper DPF delete with a quality tune usually improves 6.7 Powerstroke MPG, though aggressive driving can reduce gains.

Does a deleted 6.7 Powerstroke last longer?

Many say yes. A deleted 6.7 Powerstroke may run cooler due to reduced exhaust restriction. No regens. Lower EGTs. Cleaner oil. But risks if not tuned right. Long-term engine life depends on maintenance, driving habits, and tuning quality.

Does a DPF delete improve highway MPG more than city MPG?

Yes. Highway gains are 3–5 MPG, while city driving or towing usually improves 1–2 MPG. Highway sees bigger gains. Steady speeds benefit most from no restrictions.

Is MPG better with an eco tune or a performance tune?

Eco tunes maximize fuel efficiency and better for mileage, while performance tunes increase horsepower but may lower MPG.

How does a DPF delete compare to an EGR delete for MPG gains?

DPF deletes give bigger MPG improvements by eliminating regen cycles; EGR deletes offer minor gains. EGR helps reliability more than fuel.

How much horsepower does a delete add to a 6.7 Powerstroke?

About 40–80 HP with a proper tune and exhaust setup. Full delete plus tune: 100-150 HP gain, depending on the configuration.

Is a DPF Delete the Right Way to Improve 6.7 Powerstroke MPG?

DPF delete can enhance 6.7 Powerstroke MPG, particularly for highway drivers who have consistent fuel savings. This is especially true if you plan to keep it tuned properly and value efficiency. <Check the 6.7 Powerstroke full guide here>

But, there is a risk of being illegal, voiding your vehicle's warranty, and losing resale value. You will see less gain on city driving and heavy towing with a DPF delete.

Consider your driving habits, budget, and local regulations carefully. In most cases, a DPF delete is best for highway-focused trucks with responsible owners who understand the trade-offs.

Or if the warranty ended, you can consider a DPF delete. It does not work for daily drivers in strict states. Drive smart either way.

About the Author- John Barrett

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