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An exhaust system consists of pipes that draw gases away from the engine to the open air. When a car is running, its engine produces gases, including Carbon Dioxide, Carbon Monoxide, and Nitrogen Oxides. These gases are harmful to humans in large quantities, especially Carbon Monoxide.
This is why the exhaust system drives these gases out before they reach the cabin. So there is no denying that good quality and working exhaust system is very important in any car. We have made a list of the best exhausts for a 6.0 Powerstroke truck.
At a Glance: Our Top Picks for Exhaust For 6.0 Powerstroke
- OUR TOP PICK: MBRP S6212PLM Turbo Back Exhaust System
- RUNNER-UP: MBRP S62240PLM 5" Aluminum Turbo Back
- BEST BUDGET OPTION: Diamond Eye Performance 2003-2007
Comparison Chart of the Best Exhausts For 6.0 Powerstroke
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Are All Exhausts The Same?
Exhaust systems can vary depending on a number of different, but there are basically three different types of exhaust systems, which are discussed below.
When replacing a factory installed exhaust system, you have one of three options.
Cat-Back
This replaces everything from the catalytic converter back. They are the most used exhaust systems for different reasons, which we will discuss later.
Axle-Back
This type only replaces the mufflers of the exhaust system from the axle back. They are mainly used when you just want to improve the sound problem of your car. They are cheaper than the cat-back exhausts and have a simpler installation.
Header Back
This system replaces all exhaust system parts and requires complete installation. They are much more expensive because they include all tailpipes and mufflers. They let you increase the diameter of the system as well for a better flow of gases.
Another way one exhaust system might differ from the other is its configuration.
Single
These systems are used with smaller engines and are designed in a Y shape. They collect gas from the manifold and send it outside through a ‘single’ pipe. Some single exhaust systems can be bought with an extra tip to achieve the same look as a dual system.
Dual
Dual exhausts, as the name suggests, expel combustion gases through two pipes and are used with larger engines for more efficiency. They have separate pipes that take gases from each manifold first and then expel through two pipes. They are more expensive but also give more performance upgrades.
What is a Cat-Back Exhaust?
Cat-back gets its name from the back of the catalytic converter. This system includes tailpipes and mufflers from the back of the converter to the exhaust tips. They are the most common types of exhaust systems and are the best at improving horsepower. When installing, you can choose a different and larger diameter to improve gas flow. But you can’t go overboard with it and have to stay in the recommended limit for your engine. For a 6.0 Powerstroke, anything from a 3.5 to 4-inch is a good option.
What Should I Look For When Buying an Exhaust For My 6.0 Powerstroke?
When deciding to replace any engine part, you need to do research to make sure it is all compatible with your car and other components. If you are using a 6.0 Powerstroke, here are some of the things you should keep in mind.
Pollutants Emitted
The main reason for an exhaust system is to expel gases outside. In fact, it’s the only job of the exhaust system. A good and new system will be clean from impurities and reduce your carbon footprint.
Diameter
Larger diameter exhaust pipes are like giving your lungs more room to breathe. You need to minimize the pressure inside the pipes to pump the gases out. If your pipe is small and has kinks, the gases expelled will not be enough. This can lead to back pressure and reduced horsepower. So a large exhaust or a one with little restrictions will improve car performance.
Build Material
Look for exhaust systems that are made using stainless steel. The advantages are obvious, no corrosion, and better durability. Your car will face many different climates throughout the year; depending on where you live, it can be subjected to snow, rain, or extreme heat. A stainless steel construction will be able to better handle all that.
Help reduce air pollution.
Review of the Best Exhausts For 6.0 Powerstroke
Now that you have a better understanding of the importance and use of a car's exhaust system, let’s do the actual reviews of the best exhausts for 6.0 Powerstroke.
Best Overall:
MBRP S6212PLM Turbo Back Exhaust System
PROS
CONS
What Recent Buyers Report
Recent buyers say that the installation is not too difficult if you have the right tools, but it still takes two people to do it. There is no welding required as it has clamps to secure everything. Everything you need is included in the kit. The pipes are not too heavy and but still feel sturdy. You can notice a change in performance and sound after installation.
Why it Stands Out to Us
This is a single off-road exhaust system that has an aluminized finish to prevent rust and improve life. It attaches directly to the turbo and has a 4-inch diameter, which is considered big enough for 6.0 Powerstroke. It uses the mandrel-bent technique on pipes, which reduces kinks and aids flow.
Who Will Use This Most
It will fit all 2003-2007 Ford 6.0L Powerstroke engines. The pipe diameter is 4 inches, and the downpipe diameter is 2.3 inches. It does not include a catalytic converter, so you will need to use the factory installed one. The system will not fit Cab and Chassis models but will fit the Cab and Beds for Ford F-250 or F-350.
Bottom Line
This is a turbo-back exhaust system with aluminized steel and a 1-year warranty period. It is designed not only to give maximum fuel efficiency but also looks and sound. Using mandrel-bent tubing, you get maximum hot gases expelled, and the temperature is dropped by 200 degrees to give you optimum performance.
Runner-up:
MBRP S62240PLM 5" Aluminum Turbo Back
PROS
CONS
What Recent Buyers Report
Most users are impressed with how easy this unit is to install compared to other exhaust systems. One user has reported an increase in MPG by 7 points. It sounds very good and considering the price, it is of very high quality and durable too. Its performance invites people back for more when replacement is needed.
Why it Stands Out to Us
This system goes one step further and increases the pipe diameter to 5 inches. This means better sound and a better flow of gases. The large diameter paired with mandrel bends promises maximum fuel efficiency. The tubings are fully sealed and are aluminized to add years to the life of the system. It also improves the towing power of your truck by adding 18 horsepower and 28 ft-lbs.
Who Will Use This Most
This is a no muffler turbo-back exhaust system that fits the 2003-2007 Ford trucks of F-250 and F-350 models. The tips are not included, and you will use the factory-installed catalytic converter. The turbo downpipe is 3 ½ inches in diameter, and the exhaust system has a 5-inch diameter.
Bottom Line
This free flow muffler design is an economical alternative to more expensive exhaust systems. However, the affordable price is not attained by compromising on the quality. It uses the highest quality aluminized steel to prevent rust and make the system durable.
Best for the Money:
Diamond Eye Performance 2003-2007
PROS
CONS
What Recent Buyers Report
Users have given this product mixed reviews. It is not the best product when it comes to instructions since they result in potential leak points. But you give it to a professional to install, and it will work just fine. People who have done this before don’t have too much difficulty. They design and build quality are all up to the mark.
Why it Stands Out to Us
This system uses CNC mandrel bending machines in the construction, which gives the highest standard tubes. It’s a 4-inch replacement kit that is made from aluminized steel that helps with rust. It is a simpler system with no muffler and a good size for a 6.0 Powerstroke.
Who Will Use This Most
This exhaust system is only designed for automatic transmission cars. It will fit any Ford truck using a 6.0 Powerstroke in the 2003 to 2007 model. It can also fit all Cab and Bed sizes but not chassis.
Bottom Line
Diamond Eye Performance is one of the leading brands in diesel and gas exhausts for trucks. They use the best machines for making high-quality exhausts that have minimum restrictions and support high fuel efficiency. This replacement model is the RP type that means it does not have a muffler, but you can choose to buy it with the muffler.
Best 6.0 Powerstroke Turbo Back Exhaust:
5" Turbo Back Downpipe Exhaust System by MVP Auto Parts
PROS
CONS
What Recent Buyers Report
Buyers say that all the pipes are in the best condition, and the kit includes all the accessories you will need to install it. You do need some knowledge of the process to do it correctly. You need to cut it to fit properly at times. It sounds great as well at high RPM. It does what it is supposed to.
Why it Stands Out to Us
This is a turbo back type exhaust system. It has a large diameter of 5 inches with reduced band degree angles as well as mandrel bends to give the best fuel economy and power improvement. You also get reduced temperatures and better torque. The installation is done through simple bolt-on hangers, which are given with the kit.
Who Will Use This Most
It is a turbo-back system of 5 inches with front pipes included. The downpipe is 3.5 inches in size. Like all other systems in our list, this also fits the Ford 2003-2007 F250 and F350 Powerstroke 6.0L turbo diesel.
Bottom Line
MVP auto parts is a US-based auto parts company. This exhaust system is made from aluminized steel and is designed to provide high gas flow and improve engine performance. This is a straight pipe system with no muffler to remove restrictions in the pipe.
Best 6.0 Powerstroke Cat-Back Exhaust:
4" Aluminized Cat-Back Single Exhaust by Diamond Eye Performance
PROS
CONS
What Recent Buyers Report
Cat-back systems always offer the best performance, and this one is also of high quality and worth the trouble of installation. It sounds good and fits perfectly. The price is also very low compared to other cat-back exhaust systems. You definitely feel a boost in the performance.
Why it Stands Out to Us
This exhaust system is a 4-inch cat-back model that attaches to the catalytic converter. It is not a straight pipe design, but it comes with a muffler, which means it is legal everywhere. The muffler has a perforated tube and aluminized steel for rust resistance. This upgrade results in low EGT, more horsepower, and better sound. All hangers and clamps are included in the kit.
Who Will Use This Most
Cat-back exhaust systems are used if you need a full revamp to your system. They offer the best efficiency. It exits from the passenger side and has a 4-inch diameter to fit any 6.0 Powerstroke of 2003-2007 model.
Bottom Line
Cat-back systems are preferred over others and recommended because even though they are more expensive, the money does not go to waste. You get the most out of your engine with high gas flow, and the addition of the muffler gets rid of sound problems.
Best 6.0 Powerstroke 4 Inch Exhaust:
4" Aluminized Steel Turbo-Back Exhaust System Kit by MVP Auto Parts
PROS
CONS
What Recent Buyers Report
You will need an extra person for installation, but that goes for any exhaust system. The pipes are of high quality as well as durable. It fits perfectly in the 6.0 Powerstroke without hitting the frame or spare tire. The price is very reasonable for any turbo-back exhaust system.
Why it Stands Out to Us
This is a free-flowing pipe design that has no restrictions, so maximum gases will be expelled. It includes a downpipe of 3.5 inches that makes installation easier. You will notice better performance and lower exhaust gas temperatures. The 4-inch design is the optimum design for a 6.0 Powerstroke.
Who Will Use This Most
This exhaust system is from MVP auto parts and is 4 inches in diameter with a downpipe included, which can be bought in 4 inches size as well. The muffler is not included, and its configuration is turbo back. It will fit all extended and crew cabs and short and long beds.
Bottom Line
MVP auto parts have a wide selection of exhaust systems. This is the more economical version that uses aluminized steel instead of stainless steel, but it is still durable and of high quality. You get a boost of performance in all aspects, including sound and horsepower.
Perks of Getting a New Exhaust
If your car already has an exhaust system in it, then why go through the trouble of investing in a new one? Well, there are many reasons you need to consider upgrading, which are explained below.
Cleaner Gases
You will notice that older cars expel a lot more black gas than newer ones and are harder to start. Some of it might be due to the engine, but the exhaust system definitely plays a role. Over the years, pollutants build up and reduce the efficiency of the system. A newer system will result in cleaner gases and give your car a better look.
More Horsepower
When changing the exhaust system, you can opt for a larger diameter pipe. As we have discussed before, larger diameter means fewer restrictions and more room for the gas to flow. This makes the engine more efficient as it does not have to work against itself to fight any back pressure from leftover gases. It improves fuel efficiency and, as a result, horsepower.
Less Noise
When choosing a new exhaust system, you can replace the muffler as well. This will automatically result in less noise output and a smoother ride.
How to Install Exhaust on 6.0 Powerstroke
Installing an exhaust is not easy, and if you don’t have a lot of experience with cars and engines, then you should hire a professional. But if you are confident in your skills, then you can follow these instructions below.
- You will need a muffler, clams, piping, and tip.
- Remove the stock exhaust by cutting 3 inches in front of the catalytic converter.
- Next, cut three inches behind the catalytic converter.
- Then cut the part where it curves near the transmission and remove the cut pipe.
- Cut 2 inches behind the muffler and remove the tailpipe and then the muffler.
- Remove the clamp that attaches the exhaust pipe to the turbo.
- Put the new pipe where it goes and tighten the clamp.
- Install the pipe that needs to connect to the catalytic converter.
- At the joint, install a clamp to secure in place.
- Then attach the converter in place and install a clamp at the joint.
- Next put the muffler in the muffler hanger and then put in the first section of the tailpipe with a hanger.
- Add the next section of tailpipe and secure joint with a clamp.
- Add the adapter pipe with a clamp and measure the distance between it and the muffler.
- Cut a straight pipe of that length leaving some extra room and add it between the adapter and muffler.
- Add the hanger to the pipe and a clamp at the muffler.
- Make sure no pipe touches the frame or spare tire.
For some tips and instructions, watch the video given below.
Conclusion
Car exhausts are not the most complicated part of the combustion process but definitely one of the most important. They can have a direct impact on your engine’s health and performance. They also affect the environment in a big way, so choosing the right system for your car is very important. Even if you don’t care that much about your carbon footprint, choosing a cleaner and system always means more fuel efficiency, which means more mileage with less fuel spent. And that is something we all care about.
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