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Tool Talk Discussion Forum

4 inch exhaust on '96 Powerstroke, is it possible?

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Rich Iowa

07-30-2006 07:02:34




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Has anyone put a 4" exhaust on a 1996 Ford F250 Powerstroke diesel? I've talked to a couple exhaust shops and they said they'd have to leave the factory down pipe intact due to space restrictions and to keep some back pressure on the turbo. Am I correct in thinking the turbo doesn't need much back pressure and by leaving the down pipe would defeat putting the larger exhaust on? Also, do I have to keep the cat. converter on, that looks like that restricts the exhaust alot too. I have looked at the system that is on the truck, Ford had to flatten the down pipe to fit between the firewall and block, and between the frame and tranny. I'm not looking to get tons of power from this ugrade just help the engine breath easier, lower EGT temps, and possibly help with the milage. I'm also planning on putting an air intake kit in as well. This truck is stock, no power chips, propane, water/methanol, or anything like that, just a work truck I'd like to get as much MPG out of I can.

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Dr.EVIL

08-01-2006 08:55:08




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 Re: 4 inch exhaust on '96 Powerstroke, is it possi in reply to Rich Iowa, 07-30-2006 07:02:34  
If Your engine is stock, no chips, injectors, or drugs, the stock 3-1/2" system is enough. The larger D/P will help, that's the worst part of the stock system, followed by the CAT, which can get restricted with soot....The factory muffler is a straight thru design...very low restriction. I straight-piped My '96 about 2-1/2 yrs ago...and the OEM muffler was removed when the truck had about 10,000 miles & was 6 months old (truck rolled up 290,000 in nine years) The thing that makes the biggest difference in MPG is Your Right Foot!

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Joe-Bob/IN

07-30-2006 08:01:24




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 Re: 4 inch exhaust on '96 Powerstroke, is it possi in reply to Rich Iowa, 07-30-2006 07:02:34  
Those shops don't really know what they are talking about. You don't need any back pressure for a turbo, the more open the better. Like you say, lower EGT's are the key. Easier in, easier out, easier on the fuel. Might want to check out Kennedy Diesel or some other sites for that down pipe.



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MSM

07-30-2006 07:55:03




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 Re: 4 inch exhaust on '96 Powerstroke, is it possi in reply to Rich Iowa, 07-30-2006 07:02:34  
Try www.bigexhaust.com They carry exhaust systems from 6-7 brand name companies. I believe Bullydog has a full 4" system from the turbo back.The addition of the 4" system will result in colder exhaust temps,a slight increase in mileage and power,especially if combined with a better breathing air filter. The converter can be removed,but it depends on your local laws.If you live in a treehugging ecostate,even the addition of a 4" system with the converter installed is a violation. Use your own judgement.

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rgvtx

07-30-2006 07:25:02




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 Re: 4 inch exhaust on '96 Powerstroke, is it possi in reply to Rich Iowa, 07-30-2006 07:02:34  
I recall reading about people using the larger exhaust in an RV magazine long ago, and I also remember the discussion of the restriction in the pipe for clearance being the biggest obstacle. I know that Banks used to advertise the gains you would get with their product, and the big help was eliminating the backflow by keeping a constant size through the exhaust bends etc. Their web page shows different goodies that are supposed to help, but just like you my 96 PS is stock so I can't comment either way.

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