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Ford Power Stroke 1999 - 2003 7.3 Liter Super Duty Aluminized Systems
Diesel Performance Parts produces top quality mandrel bent aluminized exhaust systems for the 1999 to 2003 Ford Power Stroke, Super Duty trucks. Every Diesel Performance Parts system is shipped with all the necessary parts and tubing to fit any body style or bed length F250 or F350 pick up truck, with the exception of the cab and chassis models. No cutting of the tubing will be required as the system is designed to install on standard, Super and Crew Cab trucks with both short and long beds.
The Diesel Performance Parts Power Stroke systems start at the turbo charger exit with our exclusive CNC machined steel turbocharger mounting collar. The steel CNC collar Diesel Performance Parts welds to the down pipe has the same degree of contact angle as the machined mounting surface on the turbocharger. The mating of these two machined surfaces provides a 100% concentric alignment to properly secure the down pipe. The steel collar also provides a smooth flowing transition from the three inch outlet of the turbocharger through the critical first inches of the down pipe. The standard method of turbocharger attachment requires that a separate piece of three inch tubing be flared to try
to match the turbocharger outlet on one end and flared even larger on the down pipe side and then welded into the down pipe. This presents the exhaust gasses with a very abrupt dimensional change before it has traveled the first critical inches past the turbocharger exit.
The systems that are available with a four inch down pipe aggravate this situation even more, because the gap between the three inch flare and the four inch tubing is usually filled with weld and this stepped joint increases the disruption of flow volume even more dramatically! This disruption is one of the reasons these systems have a loss of low end torque. The flow changes the exhaust wave and the torque curve is moved up into the RPM band 200-300 rpm, which is exactly opposite of the reason you purchased a diesel engine in the first place, low end torque!
The Diesel Performance Parts aluminized system begins with the CNC machined steel collar that is welded to either our three and one half or four inch aluminized steel mandrel bent down pipe (view picture). The three and one half inch or our four inch down pipe then joins with the four inch aluminized steel tubing just before the transmission cross member. Joining the two pipes just before the cross member eliminates the need to remove the cross member for installation. It is much easier to cut the factory system off when the Diesel Performance Parts system is designed to install without having to remove the cross
 
member. The four inch section joins with our spiral flow core muffler just before the rear axle.
The Diesel Performance Parts spiral core muffler is six inches round by thirty inches long, containing an inner packing material made of stainless steel wool, with a ceramic wool outer packing. The interior of the muffler is a one piece four inch, aluminized steel tube that dampens the resonance of diesel exhaust and keeps the interior noise level of the cab within three
decibels of the original equipment system. The outer case of the muffler is not a sheet of flat stock rolled into a round muffler. The Diesel Performance Parts muffler starts out as a six inch diameter section of aluminized tubing. The added expense of using tubing more than justifies itself in long
product life. The first place a diesel exhaust system will usually fail is in the muffler, and almost always at the weld seam that runs the full length of the muffler case. Because Diesel Performance Parts uses factory formed tubing that potential failure problem is eliminated. Diesel Performance Parts muffler design uses a spiral flow louver that is specifically designed for diesel exhaust performance. The spiral pattern of the louvers promotes the same flow the turbocharger introduced to the exhaust gasses as they left the turbocharger. The spiral pattern of the louvers helps speed the exhaust gasses out of the exhaust system to lower the exhaust gas temperatures as quickly as possible.
The 4 inch mandrel bent tailpipe slides on the spiral flow muffler and ends with the Diesel Performance Parts five inch tip. Final positioning of the five inch T-304 polished stainless steel, rolled edge tip (view picture) and tail pipe is accomplished with the adjustment provided in the rear muffler hanger bracket. The systems that use a chrome-plated tip, unfortunately, have a very short life. The tip is located directly behind the rear wheel and is battered by road debris. The road debris will cause rust almost immediately in a chrome-plated tip, but not in a T-304 stainless tip.

The entire Diesel Performance Parts system uses welded on T-304 stainless steel hangers whenever possible to make installation an extremely easy job. Welded hangers are the most secure and permanent method of mounting, just like the original equipment system was designed. Systems that use clamp on style hangers built of mild steel are susceptible to rust and corrosion immediately after installation. The use of clamp on style hangers makes installation difficult and time consuming and generally the system does not hang on the truck as well either. Diesel Performance Parts welds on T-304 stainless steel hangers whenever possible to eliminate this problem. The joint clamps in our system are plated to further prevent corrosion and to provide a long life.

The Diesel Performance Parts Power Stroke system has been dyno tested to produce as much as 23 horsepower and 48 foot pounds of torque. (Graph) The average gains are 18 horsepower and 40 foot pounds of torque. The system will lower your exhaust gas temperatures up to 200 degrees. Mileage gains will also be related to your driving style and truck operating condition. The extra power an exhaust system provides is great, but the systems ability to lower your exhaust gas temperatures will allow you to make other performance modifications and still keep your temperatures at a safe level.

The Diesel Performance Parts aluminized systems all come with Diesel Performance Parts exclusive Five Year Replacement Warranty to the original purchaser.

1999-2003 (7.3 liter) Ford Power Stroke 3.5 inch down pipe with 4 inch complete system

1999-2003 (7.3 liter) Ford Power Stroke complete 4 inch aluminized system

1999-2003 (7.3 liter) Ford Power Stroke, Turbo Back, 4 Inch Dual System, Dual 5 Inch Stainless Steel Tips
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