2003-2007 6.0L Ford Powerstroke 3.5" Muffler & Cat Delete Pipe
Kit Add-ons
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Product Details
2003–2007 Ford 6.0L Powerstroke 3.5″ CAT & Muffler Delete Pipe
Open up the factory exhaust on your 2003–2007 Ford F-250 or F-350 Super Duty equipped with the 6.0L Powerstroke diesel engine.
This two-piece exhaust kit replaces the factory catalytic converter and muffler sections with a straight-through 3.5-inch exhaust path. Reducing these factory restrictions allows exhaust gases to exit more freely while producing a noticeably louder, deeper exhaust note and bringing out more of the 6.0L Powerstroke’s signature VGT turbo whistle.
Constructed from durable T409 stainless steel, this system is designed to withstand high exhaust temperatures, vibration, road debris, and harsh operating conditions. It connects to the remaining factory-style exhaust components using the supplied installation hardware.
Key Features
- Full 3.5-inch exhaust diameter
- Constructed from T409 stainless steel
- Replaces the factory catalytic converter section
- Replaces the factory muffler section
- Straight-through design for reduced exhaust restriction
- Louder, deeper, and more aggressive exhaust tone
- Increased audible turbo whistle
- Two-piece design for easier installation
- Designed to connect with the factory-style downpipe and tailpipe
- Installation hardware included as pictured
Vehicle Fitment
Designed for:
- 2003 Ford F-250 Super Duty 6.0L Powerstroke
- 2003 Ford F-350 Super Duty 6.0L Powerstroke
- 2004 Ford F-250 Super Duty 6.0L Powerstroke
- 2004 Ford F-350 Super Duty 6.0L Powerstroke
- 2005 Ford F-250 Super Duty 6.0L Powerstroke
- 2005 Ford F-350 Super Duty 6.0L Powerstroke
- 2006 Ford F-250 Super Duty 6.0L Powerstroke
- 2006 Ford F-350 Super Duty 6.0L Powerstroke
- 2007 Ford F-250 Super Duty 6.0L Powerstroke
- 2007 Ford F-350 Super Duty 6.0L Powerstroke
Fitment Notice
Cab style, bed length, wheelbase, and previous exhaust modifications can affect fitment. Minor trimming or adjustment may be necessary on certain short-wheelbase configurations.
Published supplier fitment information specifically excludes some 2004 F-250 XL Regular Cab and 2004 F-350 Lariat Crew Cab configurations. Customers with a 2004 truck should confirm the existing exhaust layout and measurements before ordering.
This kit is not confirmed for:
- Ford Excursion
- Ford E-Series vans
- F-450 or F-550 cab-and-chassis trucks
- Gasoline-powered trucks
- Trucks with a full aftermarket exhaust that does not use the factory 3.5-inch connection points
Exhaust Sound
Removing both the factory catalytic converter and muffler creates a substantially louder exhaust than the original system. Customers should expect:
- A deeper exhaust tone
- More pronounced turbo whistle
- Increased exhaust volume during acceleration
- Possible cabin drone at certain engine speeds
- A raw straight-pipe sound with no muffler-based sound reduction
This system is intended for customers seeking maximum exhaust sound and a straight-through exhaust configuration. It is not recommended for customers who want a quiet or near-stock exhaust tone.
Installation Information
Professional installation is recommended.
Installation generally involves:
- Allowing the complete exhaust system to cool.
- Removing the clamp and fasteners securing the factory catalytic converter.
- Installing the catalytic-converter replacement pipe.
- Measuring and cutting the factory tailpipe immediately behind the muffler hangers.
- Removing the factory muffler from its rubber isolators.
- Deburring the cut tailpipe.
- Installing the muffler replacement section.
- Loosely positioning the complete system and checking frame, body, driveline, and suspension clearance.
- Tightening all clamps and fasteners from front to rear.
- Starting the truck and checking every connection for leaks.
Cutting of the original exhaust is normally required. Rusted factory hardware, previously modified exhaust systems, or unusual cab and bed configurations may require additional fabrication.
What Is Included
- One 3.5-inch catalytic-converter replacement pipe
- One 3.5-inch muffler replacement pipe
- Installation clamps and hardware as pictured
Not Included
- Turbo downpipe
- Rear tailpipe
- Exhaust tip
- Complete turbo-back exhaust
- Electronic tuner or programming
- Replacement factory hangers
- Installation labor
Important 6.0L Exhaust Information
This product should be described as a CAT and muffler delete pipe, not a DPF delete pipe.
Ford’s 2006 documentation for the 6.0L platform references an exhaust catalyst, while Ford’s 2008 documentation identifies the diesel particulate filter as equipment used with the newer 6.4L F-Super Duty. Based on Ford’s documentation, the 2003–2007 6.0L Powerstroke should not be marketed as having the later DPF, DEF, or SCR system.
No tuning or electronic programming is included with this product. Any electronic requirements depend on the truck’s model year, factory calibration, existing modifications, and diagnostic condition.
Legal and Emissions Notice
This product replaces factory emissions-control and noise-control components. It is not represented as EPA-certified, CARB-approved, or legal for highway use.
Federal, state, provincial, and local laws may prohibit the manufacture, sale, installation, or use of products that remove or render emissions-control equipment inoperative. A product being labeled “race use,” “competition use,” or “off-road use” does not automatically make its sale or installation lawful.
The purchaser and installer are responsible for determining whether the product may legally be purchased, installed, or used for the intended application. Do not install this product on any vehicle operated on public roads where such modification is prohibited.
Shipping and Returns Policy
Important Notice: Please Read Carefully
Shipping Costs
Our shipping rates apply to orders shipped within the United States and Canada.
Shipping Times
- Air Shipping: Orders placed with air shipping by 2:00 PM EST on a business day will ship the same day.
- Ground Shipping: Our goal is to process and ship within 24-48 hours during business days, unless your order contains custom tunes that are preloaded which may take an additional 1-3 business days to ship.
Shipping Delays
Please be aware that we are not responsible for shipping delays due to weather conditions, natural disasters, or any other events beyond our control. No refunds will be issued for delays caused by such events.
Special Shipping Information
- Alaska and Hawaii:
Orders shipping to Alaska and Hawaii must select 2nd Day Air. Overnight shipping may not be available for remote areas, and these locations may experience longer delivery times than stated. - Remote Areas:
Some remote areas in Canada and other regions may incur additional shipping costs. If additional fees apply, we will notify you, and your order will be shipped once the extra shipping cost is paid. - International Shipping:
For shipping outside the US and Canada, please contact us through our contact page for assistance. - Large Packages:
All Full Exhausts, Pipes, and Air Intakes ship GROUND!
Returns Policy
- General Return Policy:
Due to the specialized nature of our products, we generally do not accept returns. Most items are VIN-specific or custom-built to order. - Defective Items:
We only accept exchanges for defective items. We recommend professional installation for these items. If a product is defective and cannot be exchanged or repaired, a refund of the original purchase price will be issued upon receipt of proof of malfunction or damage. - Return Exceptions:
In certain cases, we may make exceptions for returns. If your return request is approved, a 30% restocking fee will be applied. All items must be returned in their original packaging, and return shipping costs will not be refunded. - Cancellations:
All sales are final. If you cancel your order after it has been placed but before it has shipped, a 5% processing fee will apply. - Non-Returnable Items:
Certain items, such as hard parts (e.g., EGR kits, DPF pipes/exhaust, pyro kits, throttle valve kits, exhaust tips, and intakes), are not eligible for return unless an exception is made. If an exception is granted, a 30% restocking fee will be applied, along with the cost of return shipping.
Contact Us
Before returning any items, please contact us for specific shipping instructions.
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