Compatible 6.0 Powerstroke Engine Upgrades
- Compatible Manufacturers: Ford
- Compatible Engine Series: 6.0L Powerstroke
- Compatible Model Years: 2003–2010
These Ford 6.0 Powerstroke engine upgrades are designed for Super Duty F-Series F250/F350/F450/F550 2003–2007, Excursion 2003–2007 and E-Series Vans 2005–2010 diesel truck models.
Each component is engineered to improve the performance, reliability, and longevity of the 6.0L Powerstroke platform. Whether you are addressing common factory weak points or building a more capable towing and performance setup, these upgrades work together as a complete system.
Maximise your Ford 6.0 Powerstroke F250, F350, F450, F550 diesel truck's performance with our matched 6.0L upgrade parts bundle as below.
All EGR Performance parts are backed by our 12-month warranty – shop the bundle and save 6%!
6.0 Powerstroke EGR Delete & Emissions Solutions
Designed to address one of the most common failure points on the 6.0L Powerstroke, these EGR and emissions solutions help reduce excessive heat, coolant loss, and exhaust system restrictions.
Ideal for off-road and performance-focused builds, these upgrades improve long-term reliability and engine efficiency.
EGR Eliminator
A 6.0 Powerstroke EGR delete kit (2003-2010) removes the failure-prone factory EGR system, eliminating internal coolant leaks and reducing exhaust gas temperatures.
By replacing the stock EGR cooler with the new kit, this upgrade improves engine reliability and supports higher-performance intake, exhaust, and tuning setups. Off-road use only.
DPF Delete Kit
On late-model 6.0 Powerstroke trucks equipped with a factory DPF, the DPF system can create excessive exhaust restriction, frequent regeneration cycles, and increased exhaust heat under towing or heavy-load conditions.
A DPF delete kit helps prevent DPF clogging issues, improves throttle response, and supports higher-performance intake, turbo, and tuning upgrades. Off-road use only. Not legal for use on public roads.
1. Single Muffler Delete Pipe (Tailpipe)
This one-piece 3.5-inch 6.0 Powerstroke muffler delete CAT pipe (2003-2007) is ideal for custom exhaust setups or customers who already have clamps and hardware.
Precision-formed tubing ensures proper exhaust alignment and durability, making it a simple and effective exhaust upgrade for performance or off-road applications. Professional installation recommended. Off-road use only where applicable.
2. Muffler Delete Pipe Kit (Two Pipes with Clamps)
Featuring two precision-bent 3.5-inch 6.0 Powerstroke muffler delete pipes with Clamps (2003-2007) and included exhaust clamps, this kit provides a clean, leak-free solution for deleting the muffler. Reduced exhaust restriction helps improve turbo spool, lower EGTs, and deliver a deeper, more aggressive exhaust tone.
Ideal for performance builds and off-road trucks looking for an easy, no-weld installation. Off-road use only where applicable.
Tuning & ECU Performance for 6.0 Powerstroke
Proper tuning is essential when upgrading airflow, exhaust, or emissions components. These 6.0 Powerstroke tuning solutions unlock horsepower and torque while maintaining safe engine and transmission operation.
Tuner
This 6.0 Powerstroke tuner (2003-2016) delivers optimised fuel delivery, boost control, and transmission tuning. Also fits 6.4 Powerstroke and 6.7 Powerstroke.
It is required for Powerstroke EGR DPF delete tuning and works best when paired with intake, intercooler, and exhaust upgrades for maximum performance gains.
Ford 6.0 Intercooler Upgrade & Intake System Performance
Upgrading the intake and charge-air systems is critical for controlling EGTs and improving power output on turbocharged diesel engines. These 6.0 Powerstroke intake system upgrades increase airflow efficiency and support reliable performance under load.
Intercooler
This direct-fit 6.0 Powerstroke intercooler (2003-2007) cools compressed intake air, reducing EGTs and increasing air density. It is a core component of any upgraded 6.0 Powerstroke intake system, especially for towing or high-boost applications. Cooler air improves combustion efficiency, horsepower, and long-term engine reliability.
Intake Pipe
It is a key component of any upgraded 6.0 Powerstroke intake system. A high-flow 6.0 Powerstroke intake pipe (2003–2007) replaces restrictive factory tubing to improve airflow to the turbocharger. Reduced restriction helps decrease turbo lag, improve throttle response, and support higher horsepower levels as part of a complete intake upgrade.
6.0 Ford Powerstroke Turbo & Exhaust Flow Components
These 6.0 Powerstroke exhaust upgrades improve exhaust flow from the manifolds to the turbocharger, addressing common factory failures and helping maintain consistent boost pressure.
UP Pipe / Y-Pipe
This heavy-duty 6.0 Powerstroke Y-pipe and up-pipe assembly (2003–2007) replaces restrictive and leak-prone factory exhaust piping. By eliminating cracked bellows, it restores proper exhaust flow to the turbo, improves boost consistency, and helps control EGTs. A critical reliability upgrade for towing and tuned trucks.
Down Pipe
This mandrel-bent 6.0 Powerstroke 3.5-inch down pipe (2003–2007)improves exhaust flow exiting the turbocharger, reducing backpressure and lowering EGTs. It is a must-have upgrade for performance-tuned or heavy-duty towing Ford 6.0 Powerstroke trucks.
Exhaust Manifold Header
Heavy-duty 6.0 Powerstroke exhaust manifold headers (2004-2010) resist cracking and warping under high exhaust temperatures. Improved exhaust flow ensures consistent turbo performance and long-term reliability, installing as a direct replacement for factory manifolds.
6.0 Powerstroke Cooling & Oil System Upgrades
Cooling and oil system reliability are critical on the 6.0L Powerstroke. These upgrades are designed to protect the oil cooler, prevent leaks, and reduce heat-related failures.
Oil Cooler Gaskets
These premium 6.0 Powerstroke oil cooler gaskets (2003-2007) prevent oil-to-coolant cross-contamination, one of the most notorious 6.0L engine issues. Essential when replacing or servicing the oil cooler.
Coolant Filtration
This 6.0 Powerstroke coolant filtration kit (2003-2007) removes casting sand and debris from the cooling system, protecting the oil cooler and EGR cooler. It significantly improves long-term reliability, especially on engines running an EGR delete for 6.0L Powerstroke.
6.0 Ford Powerstroke Fuel Pressure Upgrade
Maintaining proper fuel pressure is critical for injector life on the 6.0L Powerstroke. These upgrades help prevent costly injector failures.
Fuel Pressure
This 6.0 Powerstroke fuel pressure upgrade (2003-2007) stabilises PSI to protect injectors from low-pressure damage, one of the most common causes of injector failure on the 6.0L engine. It installs on the factory fuel system for consistent PSI.
6.0 Powerstroke Electrical & Engine Control Components
Electrical reliability is a common issue on the ageing 6.0 Powerstroke. These components restore proper signal and power delivery throughout the engine.
Engine Wiring Harness
This OEM-style 6.0 Powerstroke engine wiring harness (2003-2007) restores stable electrical connections to injectors, sensors, and the FICM. It eliminates misfires, no-start issues, and intermittent electrical faults with a plug-and-play installation.
Glow Plug Harnesses
OEM-style 6.0 Powerstroke glow plug harnesses (2004-2010) ensure consistent voltage delivery for reliable cold starts. They replace brittle factory wiring with direct-fit connectors for dependable operation.
Ford 6.0 Cooling & Accessories
Supporting cooling components play a key role in engine longevity, especially under towing or high-load conditions.
Fan Clutch Adapter
This 6.0 Powerstroke fan clutch adapter (2003-2007) ensures proper fan engagement and cooling performance. It helps prevent overheating and installs between the fan clutch and engine for precise 6.0L fitment.
