The Complete Guide to 6.0 Powerstroke Delete Kits: What Gets Removed and Why

What a 6.7 Powerstroke EGR Delete Kit Removes

A 6.7 powerstroke egr delete kit removes the exhaust gas recirculation system that routes exhaust gases back into the intake manifold, along with the cooler, valves, and sensors that support it. While this guide focuses on what gets removed in a delete kit installation, understanding the differences between the 6.0 and 6.7 Powerstroke systems helps you choose the right components for your specific engine.

Both the 6.0 and 6.7 Powerstroke diesels use EGR systems to reduce nitrogen oxide emissions, but they're engineered differently and require distinct delete approaches. The 6.7 features a high-pressure and low-pressure EGR circuit, while the 6.0 relies on a simpler single-loop design that's notorious for cooler failures.

Core Components Removed in a 6.0 Powerstroke Delete

When you install a 6.0 powerstroke delete kit, you're eliminating several failure-prone parts that Ford owners frequently replace. The 6.0 system includes an EGR cooler that sits in the valley between the cylinder heads, an EGR valve that meters exhaust flow, and the intake plumbing that connects them.

The typical egr 6.0 delete kit replaces these components with:

• EGR cooler delete pipe – bypasses the factory cooler entirely
• Intake manifold gaskets – seal the openings left by removed EGR piping
• Up-pipe modifications – block exhaust gas from entering the EGR circuit
• Throttle valve delete or block plate – removes another common restriction

An egr block off plate seals the manifold ports where the EGR valve and cooler originally connected. These plates are precision-machined to match the manifold surface and prevent exhaust leaks or unmetered air from entering the intake system.

How the 6.7 Powerstroke System Differs

The 6.7 Powerstroke uses a dual-circuit EGR design that's more complex than the 6.0 setup. High-pressure EGR draws exhaust upstream of the turbo and routes it through a dedicated cooler, while low-pressure EGR takes exhaust downstream of the diesel particulate filter and reintroduces it after the intercooler.

This means a complete egr delete kit 6.7 powerstroke must address both circuits, plus the associated sensors and control modules. The process requires blocking off multiple ports, rerouting coolant lines that fed the EGR cooler, and often reprogramming the ECU to prevent fault codes.

Year-specific considerations matter here. A 2012 6.7 powerstroke egr delete kit uses slightly different hardware than kits designed for 2016, 2018, 2021, or 2022 model years due to running changes Ford made to the EGR valve design and sensor locations. Always verify the kit matches your truck's build date before installation.

You can explore the pros and cons of 6.7 Powerstroke EGR delete kits to understand the trade-offs involved in this modification.

What About EGR Delete Without Removing the EGR

Some installers pursue a 6.7 powerstroke egr delete without removing egr hardware, instead using block plates and tune files to deactivate the system while leaving the cooler and valve in place. This approach simplifies installation and keeps the engine bay looking stock, but it wastes the bay space and doesn't eliminate the weight of the factory cooler assembly.

The benefit is easier reversal if needed, and it avoids cutting or permanently modifying coolant hard lines. However, most enthusiasts prefer complete removal to maximize underhood airflow and reduce heat soak from the dormant cooler.

Supporting Components You'll Need

Beyond the EGR hardware itself, a proper delete often requires additional parts to address related emissions equipment:

• DPF and DOC delete pipes – replace the diesel particulate filter and catalyst
• SCR delete – removes the selective catalytic reduction system on 6.7 engines
• O2 spacer or mini catalizador o2 sensor spacer – prevents oxygen sensor fault codes after removing the catalyst
• Custom tuning – reprograms the ECU to disable emission system monitoring

An egr block off plate is often sold separately from full kits, giving you the flexibility to block individual ports if you're doing a staged delete or only removing specific components. These plates work equally well on 6.0 and some 6.7 applications depending on flange size and bolt pattern.

For pricing on complete kits and block plates, check our current codes before you order.

Installation Difficulty and Tools Required

The 6.0 delete is generally more straightforward than the 6.7 because you're dealing with a single EGR loop and fewer sensors. Expect to spend four to six hours on a 6.0 install if you're methodical, versus six to eight hours on a 6.7 due to the dual-circuit teardown and coolant line rerouting.

Ford 6.7 egr delete instructions vary by kit manufacturer, but most follow this sequence:

1. Drain coolant and disconnect batteries
2. Remove intake piping and intercooler boots
3. Unbolt EGR cooler and valve assemblies
4. Install block plates with new gaskets
5. Reroute or plug coolant lines
6. Reinstall intake components and refill coolant
7. Flash ECU with delete-compatible tune

You'll need basic hand tools, a torque wrench, and a way to lift the truck safely. Some 6.7 kits require cutting factory exhaust pipes, so a sawzall or pipe cutter speeds the job significantly.

Choosing the Best Kit for Your Powerstroke

The best 6.7 powerstroke egr delete kit for your truck depends on whether you want a budget block-plate solution or a complete system that includes DPF and SCR removal. Full race kits cost more but eliminate every restriction in the exhaust and intake path, while EGR-only kits leave the DPF in place and are easier to reverse.

For 6.0 owners, prioritize kits that include quality gaskets and stainless steel block plates. The 6.0's EGR cooler is a known weak point, so permanent removal beats trying to maintain the factory setup with upgraded coolers.

We've tested kits across multiple model years and found that machining quality on the block plates matters more than brand hype. A poorly finished plate will leak boost or create vacuum leaks that hurt performance worse than leaving the EGR installed.

Grab our discount code to save on the parts you need, whether you're building a 6.0 or tackling the more complex 6.7 system.

Legal and Warranty Considerations

Removing emissions equipment violates EPA regulations for on-road use in the United States and will void your powertrain warranty. These kits are sold for off-road and racing applications only. Many states require emissions testing, and a deleted truck will fail visual and OBD-II inspections.

We cover delete kits because they're popular performance modifications, but we recommend understanding your local laws and intended use before purchasing. If your truck sees street duty, consult local regulations and consider whether the performance gains justify the legal risk.

For trucks used exclusively on private property, in competition, or in regions without emissions enforcement, a delete kit can extend engine life by eliminating the heat and soot recirculation that accelerates wear. The choice depends on your specific situation and risk tolerance.