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8 Best 6.4L Powerstroke Performance Upgrades

2008-2010 Ford Superduty with 6.4L Powerstroke diesel engine Performance Upgrades

Must-Have 6.4L Powerstroke Performance Upgrades

The 6.4L Powerstroke is a powerhouse, with all sorts of untapped potential. Tons of horsepower and torque can be added very easily. Even with the emissions in-tact, you can cross 500 horsepower without breaking the bank. Horsepower and torque aren’t all that is important though. Fuel Economy and Reliability are just as important. While the 6.4L Powerstroke features great performance potential, there is a lot to be desired from a fuel economy and reliability standpoint. There are a number of 6.4L Powerstroke accessories and aftermarket parts that can not only make these trucks more reliable, but also increase horsepower, torque and overall fuel economy. So what 6.4L Powerstroke upgrades can be done to boost fuel economy and reliability? Here are our favorite 6.4L Powerstroke Performance Upgrades.

7 Best 6.4L Powerstroke Upgrades

1. Performance Monitors & Gauges

Monitors are number one on my list of the best 6.4L Powerstroke performance upgrades. Everyone can benefit from a monitor or gauge display in their truck. They give you real time data and analytics about your truck’s performance. They also let you read diagnostic trouble codes, or DTCs. This makes identifying many common problems very easy as the DTC will point you in the right direction. Some 6.4L Powerstroke problems aren’t easy to identify however, like a clogging oil cooler. A DTC code may present itself or may not. If you observe a high delta between the engine coolant temperature and oil temperature, it can usually be traced to a clogged oil cooler. With the right parameters displayed, you could easily identify this problem.

We’ve reviewed two separate monitoring devices that would make a great addition to your 6.4L Powerstroke, the Edge CTS2 Insight and the Bully Dog BDX. Here’s a quick summary of what they offer.

Edge CTS2 Insight $430

Monitors like CTS2 Insight from Edge give you real time data and analytics on your truck’s performance. You can keep an eye on important parameters, adjust numerous truck settings, and even connect a rear-view camera to the Edge CTS2 Insight. Read my full CTS2 Insight Review for more information.

Bully Dog BDX - Diesel Performance Tuner & Monitor Device
Bully Dog BDX Programmer & Monitor

Bully Dog BDX $399

The Bully Dog BDX not only offers real time data about your truck’s performance, but it also offers stock, “box” tunes and custom tuning capabilities via the cloud. Read our full Bully Dog BDX review for more information.

2. Engine Coolant Filtration Devices

Number 2 on our list of the best 6.4L Powerstroke performance upgrades is engine coolant filtration systems. Engine Coolant filtration systems are a must-have for any 6.4L Powerstroke. The EGR emissions system uses coolant/anti-freeze to lower the temperature of hot exhaust gases that are re-introduced into the engine. While this process greatly reduces the amount of nitrogen oxides being emitted from the tailpipe, engine coolant break down occurs from the hot temperatures that it’s exposed to. Engine coolant filtration systems help maintain engine coolant quality by catching any particulate or break down in a filter. This can greatly reduce the amount of problems, and extend the life of your coolant, oil cooler, EGR, and water pump.

Here are two 6.4L Powerstroke Coolant Filtration Systems you should consider.

Mishimoto Coolant Filtration System $160

The Mishimoto Coolant Filtration system filters solid particles from coolant. This helps extend the life of your oil cooler, EGR, water pump, and coolant. As with all Mishimoto products, it comes with their lifetime warranty.

Sinister Diesel Coolant Filtration System $165-$185

The Sinister coolant filtration system helps extend coolant life. They offer both a WIX and a CAT Filter that are available with their filtration systems. It also comes with a lifetime warranty.

3. Aftermarket Radiator

2008-2010 Ford Superduty trucks with the 6.4L Powerstroke diesel engine are notorious for cracking radiators. The plastic ends of the radiators are prone to cracking over time from vibration and stress. If you’re eventually going to have to replace your 6.4L Powerstroke’s OEM radiator anyways, why not give your truck an upgrade? Check out our favorite aftermarket 6.4L Powerstroke all-aluminum radiator.

Mishimoto Aluminum Radiator $853.99-$1,400

The answer to 6.4L Powerstroke coolant leaks stemming from a poorly designed OEM radiator. Mishimoto designed an all-aluminum radiator, backed by a lifetime warranty. Mishimoto’s aluminum radiator features an updated mounting design to reduce radiator stress and a magnetic drain plug. Can be paired with an upper support bar kit for greater reliability.

4. Tuners & Programmers

The quickest way to add horsepower and torque to your 6.4L Powerstroke is by purchasing a tuner or programmer. Tuners and programmers adjust different engine parameters like fueling to improve performance. They can also adjust transmission parameters to improve shift points. There are a lot of tuners out there, but the best results will be achieved by custom tuning. Be cautious though as tuning can result in costly repairs. There are often other parts that need to accompany tunes like head studs, beefier transmission parts, and fuel system upgrades. Here are some 6.4L Powerstroke tuners we recommend.

Bully Dog BDX Programmer With Custom Tuning $399+

Want tuning and data monitoring from one unit? Bully Dog’s BDX programmer is the perfect solution for you. I’ve used it personally on a ’14 Powerstroke with tunes from Innovative Diesel. I was so impressed with the product and the custom tunes. Tune delivery can be done over the cloud too which is a huge plus!

Banks Six Gun Diesel Tuner for the 6.4L Powerstroke
Banks Six Gun Diesel Tuner – 6.4L Powerstroke
Photo Courtesy of Banks Power

Banks Six Gun Diesel Tuner $617

If you want clean, reliable performance for your 6.4L Powerstroke, who better to trust than Banks Power. The Banks Power Six Gun Diesel Tuner offers gains of up to 101 horsepower and 193 lb-ft of torque. It’s even 50 state carb-compliant!

5. Cold Air Intake

A cold air intake will give your 6.4L Powerstroke cooler, denser air which translates to performance gains and better fuel economy. They’re also very affordable and easy to install. This makes cold air intakes one of the best basic 6.4L Powerstroke performance upgrades, especially for first-time diesel owners who want to install aftermarket parts by themselves. Check out our favorite 6.4L Powerstroke cold air intakes below.

Banks Ram Air Intake System $429

This cold air intake has been proven itself capable of outflowing the stock air intake by up to 31%. Banks 6.4L Powerstroke Ram Cold Air Intake gives your engine the cold, dense air it needs to be more efficient. It’s also easier to service and it’s more flexible than the stock air intake, providing better durability.

S&B Cold Air Intake 2008-2010 Ford Superduty with 6.4L Powerstroke Engine - Easy 6.4L Powerstroke upgrades.
S&B Cold Air Intake For 2008-2010 Ford Superduty with 6.4L Powerstroke diesel engine
– Photo taken by SBFilters

S&B Cold Air Intake $299-$350

Want noticeable performance improvements that looks great underneath the hood? The S&B 6.4L Powerstroke Cold Air Intake system looks great, performs well, and is easy to service! The see-through top makes it easy to know when your air filter needs to be changed. They also washable filters on their cold air intakes!

6. Aftermarket Up-Pipes

Are you finding absurd amounts of soot on the inside of your hood, on your firewall, or covering the transmission casing? You could also be hearing a loud hissing noise. The 6.4L Powerstroke’s factory up-pipes are prone to failure at the expansion joints. It’s not a matter of if, it’s a matter of when you are going to replace them.

Rudy’s Diesel Heavy Duty Replacement Up Pipes $350

Rudy’s Diesel makes a heavy duty up pipe kit that works with the factory EGR set-up. They also offer a superior thick-wall stainless steel composition and a lifetime warranty! They’re also completely bolt-in and don’t require switching to 6.0 Headers.

7. Larger Intercoolers

Aftermarket Intercoolers make an excellent addition to any diesel truck. They provide cooler, denser air to the engine that can lead to respectable power improvements. They also lower EGTs and increase fuel economy. It’s hard to think of a reason not to invest in one. Here are some aftermarket intercoolers we recommend as an upgrade for your 6.4L Powerstroke.

Banks Intercooler Upgrade 6.4L Powerstroke
Banks Techni-Cooler Intercooler for the 6.4L Powerstroke

Bank’s Power Techni-Cooler Intercooler Upgrade $1,300-$1,400

Want cooler, denser air and a 14% improvement in air flow over your stock intercooler? The Bank’s Techni-Cooler Intercooler Upgrade for the 6.4L Powerstroke is an upgrade that will give you more power, reduce EGTs, and even improve fuel economy.

Mishimoto Intercooler Upgrade $1,000-$1,400

Another Mishimoto product makes our list of the best 6.4L Powerstroke upgrades. Mishimoto’s 6.4L Powerstroke intercooler upgrade helps lower egts, increase fuel economy, and improve power.

8. Exhaust Systems

Factory exhaust systems are very restrictive. Emissions are a huge contributing factor to exhaust system inefficiencies. A true straight-pipe style exhaust is the best way to improve overall exhaust flow. Unfortunately, it’s federally illegal to remove emissions devices from your vehicle, so unless your vehicle is strictly used for offroad racing or events that’s not an option. What you can do however, is purchase a DPF-back exhaust system. It won’t require the use of delete tuning, and it won’t void any factory warranty you have.

Banks Power Monster Exhaust 6.4L Powerstroke
Banks Monster Exhaust for 6.4L Powerstroke

Banks Monster Exhaust $409

Reduce backpressure and increase exhaust flow from the DPF-back. The Bank’s Power Monster exhaust system is a true 4″ DPF-Back exhaust system for the 6.4L Powerstroke. All necessary hardware and clamps included for a bolt-on installation!

Diamond Eye Exhaust System for 6.4L Powerstroke
6.4L Powerstroke Diamond Eye Exhaust System Upgrade

Diamond Eye Performance Exhaust $200

Here’s another 6.4L Powerstroke exhaust system upgrade. The Diamond Eye Performance DPF-Back exhaust system is easy to install and improves performance at an affordable price. If your budget is your main concern this is a great option!

Learn More About the 6.4L Powerstroke

Check out our other 6.4L Powerstroke resources. Click on one of the links below.

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Founder of Diesel Resource and a complete diesel head. Has a little bit of problem buying too many trucks. Learn more about him by checking out his truck.