2003–2007 Ford 6.0L Powerstroke 3.5″ CAT & Muffler Delete Pipe | F-250/F-350 Super Duty

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:

1. Allowing the complete exhaust system to cool.
2. Removing the clamp and fasteners securing the factory catalytic converter.
3. Installing the catalytic-converter replacement pipe.
4. Measuring and cutting the factory tailpipe immediately behind the muffler hangers.
5. Removing the factory muffler from its rubber isolators.
6. Deburring the cut tailpipe.
7. Installing the muffler replacement section.
8. Loosely positioning the complete system and checking frame, body, driveline, and suspension clearance.
9. Tightening all clamps and fasteners from front to rear.
10. 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.