While you spend a lot of time caring for your Ford truck, it’s unlikely that you regularly think about the exhaust. However, with a simple exhaust upgrade, you can enjoy more efficiency and better performance. So, how do you find the best exhaust for 7.3 Powerstroke trucks? It might not be as complicated as you would think.
There are a lot of companies offering 7.3 Powerstroke exhaust systems, but they aren’t all created equally. That’s why you need a professional to guide you through all of the junk. We found several top exhaust models that are worthy of being installed on your Ford diesel truck. In our comprehensive guide, we look at these models and help you understand the exhaust system better.
Table of Contents
What is a 7.3 Powerstroke Exhaust?
Your Ford exhaust system is meant to remove gases that come from the engine and send them into the atmosphere. Inside the engine, various gases are being produced. These gases include carbon dioxide, carbon monoxide and nitrogen oxide, all of which can be harmful and should be avoided.
When you install a high-performance exhaust to your 7.3 Powerstroke engine, you guarantee that these gases get where they belong. Plus, a high-quality exhaust keeps your truck motor running the way it is meant to be.
Understanding the 7.3 Powerstroke Exhaust System
The Powerstroke exhaust system contains a few different parts that work together in harmony. Here are some of the major parts you want to understand.
Ford Exhaust Manifolds/Headers
When combustion happens in the engine, exhaust gas gets pushed out of the cylinders with the help of the pistons. These gases travel into the exhaust manifold, which is a vital component bolted to the engine head. You will notice a pipe attaches securely to each cylinder, meant to collect gases and push it to the exit pipe or collector.
The stock manifold is often made with cast iron, which is inefficient. Instead, you want to swap this part for a high-performance model to gain better efficiency.
Ford Catalytic Converters
Inside the catalytic converter, the dangerous materials from the exhaust get turned into something safer. Palladium mixes together with the pollutants and starts a chemical reaction. What happens is the gases get turned into better byproducts, such as water vapor, nitrogen and oxygen, before these gases mix with the atmosphere.
When the air/fuel ratio is off in the engine, the catalytic converter can go bad. If that happens, you are going to have a much larger repair bill because this is an expensive component.
Ford Mufflers
If there wasn’t a muffler on your Ford truck, you would hear an annoying exhaust sound, unlike the aggressive tone you are looking for. The muffler reduces the sound, making it less deafening.
Most mufflers contain a resonating chamber that contains baffles to reduce the sound waves. Performance mufflers have resonating chambers that also amplify and tune the note, so you get a deeper tone. Mufflers come in a variety of inlet/outlet configurations, ensuring you get the style you want.
Ford Exhaust Tips
At the end of the muffler, you will find exhaust tips. This is the furthest part from the engine, but the diameter of the tips and the bend will still have an effect on performance. If you go with a wide diameter, more exhaust gas can flow, relieving backup. You might decide to end the Ford exhaust at the muffler, but this doesn’t have a great appearance. Instead, install a simple exhaust tip that will turn heads.
Choosing a New Exhaust for 7.3 Powerstroke
When you are ready to buy a new exhaust for your Ford truck, you want to consider the options based on these factors.
Compatibility
If you need a Ford SuperDuty exhaust for your 7.3 Powerstroke, you won’t automatically look at 6.0 Powerstroke exhausts. These are different models, so you aren’t going to get the right fit. Instead, look for an exhaust based on the model year and truck that you own.
Efficiency
The exhaust needs to be efficient to ensure pollutants don’t get into the air. Aftermarket exhaust systems clean out the impurities better before they reach the atmosphere, reducing the carbon footprint.
Type
The Ford Powerstroke exhaust can come in a variety of styles. If you choose a cat-back exhaust system, you get all of the parts from the catalytic converter back. When you search out a Super Duty truck exhaust, these are going to be the most popular choice. With this option, you can upgrade the diameter of the pipe to create streamlined gas flow, which increases the horsepower.
The axle-back exhaust replaces the muffler and other components after the axle. It will improve the sound quality and comes at a lower cost than the cat-back but won’t offer as much performance. Plus, it is simple to install. If you want to go all the way, you will choose a header back exhaust. This type replaces every exhaust system component coming off of the header moving toward the back of the truck. Obviously, this will be the most expensive option, but also offers you a big increase in performance.
Exhaust Pipe Diameter
When you use a piping system with a larger diameter, the engine can breathe easier. The gas won’t build up as much because there is less pressure. On the flip side, small pipes or an exhaust that has bends and turns traps the gas, creating back pressure, which reduces horsepower and performance.
Exhaust Material
There are many exhaust materials the parts could be made from. Mild steel exhaust parts are cost-effective. However, the stainless steel components offer more corrosion-resistance and tend to last longer.
Single vs. Dual Exhaust
The single exhaust normally sits on a smaller engine type. It contains a Y-shape that traps the gases at the manifold and sends it out through a single exhaust pipe. You can add a tip to these exhaust systems to create the look of a dual exhaust, but that does nothing to affect the performance. However, the single exhaust is the lowest-cost way to upgrade an exhaust. If you prefer, you can choose a dual exhaust system to expel the gases through two pipes. With a larger engine, this is the best way to handle the exhaust if you plan to boost efficiency and performance. In this configuration, there are two pipes coming from the manifold to expel the gases out of the back. Of course, the extra pipe means more installation time and a higher price tag.
Price/Warranty
Your main goal might be to save money on a new exhaust, but that’s not advised. Sure, getting a deal is always a good thing. However, it’s not good to sacrifice any amount of quality to save some change. We recommend that you pick an exhaust system created by a reputable brand for the best performance. You can read through customer reviews to get a feel for the durability and performance. Plus, a warranty adds more value to the mix.
Best 7.3 Exhaust – Top 4 Evaluated
1. Banks 48659 Monster Review – Best 7.3 Powerstroke Exhaust
This four-inch exhaust system cuts down backpressure by up to 81% and can also lower the exhaust gas temperature. With its throaty sound, you are sure to gain a lot of attention. Banks is a known name in performance exhausts and this option is no different.
It is constructed from stainless steel, ensuring maximum durability and a streamlined pathway for exhaust gases. Plus, the special expansion chamber in the muffler dissipates annoying mid-range tones, commonly included with straight-through exhaust systems.
You are going to spend a premium price on this performance exhaust. However, the reviews prove it is a top choice and you get a 5-year warranty. If you want the best, you need to be prepared to pay for it.
Features:
- Fits: 1999-2003 Ford 7.3 Powerstroke
- Material: Stainless Steel
- Type: Cat-back
- Exit: Single
- Diameter: 4″
- Warranty: 5-Year
- Unique Expansion Chamber
| Pros | Cons |
| Banks performance | High price |
| Aggressive, throaty tone | |
| Durable construction | |
| Comes with a 5-year warranty |
2. Diamond Eye K5252A Review – Best Exhaust for Fuel Economy
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You don’t need to spend more than necessary to get a decent exhaust that boosts performance and fuel economy. This 5″ aluminized single back exhaust provides a boost to fuel efficiency while making your truck more responsive for heightened enjoyment.
Plus, you can enjoy the rich and mellow note the exhaust puts out. Even if you don’t have a lot of tools at home, you should be able to get this installed with some simple hand tools. That is, unless you have piping that needs to be cut off.
This non-restrictive exhaust kit comes with everything you need to complete the exhaust, including the hardware, clamps and hangers. However, the muffler is not included, so you will need to factor that into the overall cost. Thankfully, the company extends a one-year warranty to you for peace of mind.
Features:
- Fits: 1994-1997 Ford 7.3 Powerstroke
- Material: Aluminized Steel
- Type: Cat-back
- Exit: Single
- Diameter: 5″
- Warranty: 1-Year
- Complete Kit
| Pros | Cons |
| All hardware included | Does include muffler |
| Reasonable price | Not stainless steel |
| Mellow exhaust note | |
| Boost in fuel economy |
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3. Upower 4″ Inlet Diesel Exhaust Muffler Review – Best 7.3 Powerstroke Muffler
While a new muffler isn’t going to provide as much performance as an entire exhaust system, it is a vital part of the upgrade. With some exhaust systems, such as the one above, you will need to purchase the muffler separately.
With the 4″ diameter, there is plenty of room for exhaust gases to escape. Plus, the company uses a 100% welded design to create more durability. This construction combines with the stainless steel material to offer a longer life, thereby giving you the best value possible.
The CRF (Continuous Roving Fiberglass) technology helps absorb unwanted interior resonance. Additionally, the company offers a one-year warranty, so you know your money isn’t wasted. Speaking of money, this may not be the cheapest muffler on the market, but it is still a good value, especially when you consider the exceptional reviews.
Features:
- Fits: 1994-2003 Ford 7.3 Powerstroke
- Material: Stainless Steel
- Type: Muffler
- Exit: Single
- Diameter: 4″
- Warranty: 1-Year
- CRF (Continuous Roving Fiberglass) Technology
| Pros | Cons |
| Durable construction | Only a muffler |
| Good customer reviews | |
| Increases exhaust flow | |
| Better sound quality |
- Inlet: 4" inner diameter - Outlet: 4" inner diameter - Overall Length: 30" - Body length: 24" - Body type: 7" round - style: Both ends can be inlet, no inlet or outlet difference.
- 100% welded design for long-lasting durability
- Stainless steel construction for lifelong protection
- CRF (Continuous Roving Fiberglass) technology absorbs unwanted interior resonance
- Upower Exhaust Tip: Before purchasing, please make sure the Brand Logo is "Upower".
4. Upower Diesel Exhaust Tip Review – Best 7.3 Exhaust Upgrade
If you want to make a simple upgrade to the exhaust system but don’t have the money to spend on all of the parts, you could install a new tip. This exhaust tip fits on the 4″ piping and provides a 6″ outlet pipe. Overall, it measures 18″ long and provides a superior look.
Plus, the tip simply bolts on in place of the previous tip. This offers the best option for novice mechanics. With the mirror polished stainless steel finish, you are going to gain more attention everywhere you go. You aren’t going to see much of an improvement in terms of performance, but the aesthetics will get a big boost.
The anti-corrosion tip is sure to last. However, the company also provides a one-year warranty to ensure further protection. Upgrade your truck, so it looks like a million bucks, but do it on a cheapskate budget.
Features:
- Fits: 1994-2003 Ford 7.3 Powerstroke
- Material: Stainless Steel
- Type: Tailpipe
- Exit: Single
- Diameter: 4″
- Warranty: 1-Year
- 18″ Long
| Pros | Cons |
| Simple installation | Only the exhaust tip |
| Good customer reviews | |
| Cheap | |
| Durable construction |
Benefits of Installing the Best Exhaust for 7.3 Powerstroke
Why would anyone want to install a new exhaust on their Ford truck? Aside from needing a new one because the old one no longer works or is damaged, here are a few benefits to consider.
Optimized Efficiency
Your old Powerstroke engine shoots out a lot of damaging gases into the atmosphere. When you upgrade the exhaust, you protect the environment and help your engine run cleaner.
Enhanced Style
With an aftermarket exhaust for your Ford truck, you can change the style of your pickup. Look for a polished tip design to turn heads.
More Performance
If you choose an exhaust with a large diameter pipe, there are fewer restrictions, allowing the gases to flow better, so the engine operates more efficiently. As the engine is optimized, there is an increase in horsepower and reduced back pressure, causing better fuel economy too.
Superior Sound
When you replace the muffler, you can change the sound of your exhaust. Whether you choose to muffle the sound more or create an aggressive tone, it is completely customizable to your needs.
Symptoms of a Bad 7.3 Powerstroke Exhaust System
How do you know when the exhaust on your 7.3 Powerstroke is starting to fail? Here are a few symptoms to look for.
- More Noise than Normal: If one of the pipes is leaking or cracked, there will be more noise.
- Physical Imperfections: If you notice pipes hanging below the truck, something might be broken or corroded.
- Raw Fuel Smell: If the exhaust is failing, you could smell raw fuel, which could also infiltrate the truck cabin.
- Performance Decrease: If you notice a decrease in acceleration, power or fuel efficiency, there could be a problem with the exhaust.
Installing a New Exhaust for Your 7.3 Powerstroke
Replacing a 7.3 Powerstroke exhaust isn’t for the fainthearted. It helps to have some advanced mechanical skills and upgraded tools. Here are a few basic instructions that might help you.
- Park your Ford pickup on a flat surface.
- Keep the engine off while you work on it.
- Raise your truck and secure it.
- Use a penetrating catalyst to spray down the hardware. Allow it to soak.
- Remove your stock exhaust. In some cases, you might need to cut the pipes.
- Remove the hangers and install new ones.
- Replace all of the gaskets.
- Install the new exhaust system that you picked out above.
- Secure the hangers and clamps, so the exhaust is held in place.
- Look over your work and check for any issues.
- Lower your pickup and take a test drive.
Here’s one example of how to replace a 7.3 Powerstroke exhaust system.
7.3 Exhaust System FAQs
What is the 7.3 Powerstroke?
The very first Powerstroke is the 7.3 Powerstroke diesel engine. It was originally released during the 1994 model years and continued until 2003 when the 6.0L Powerstroke took over. It remains one of the most popular Powerstroke options among enthusiasts.
What is the cost to replace a 7.3 Powerstroke exhaust?
It’s not difficult to spend $1,000 or more on a 7.3 Powerstroke exhaust replacement. However, you can choose options that are cheaper than this and you can perform the installation yourself to save more money.
Does a new 7.3 diesel exhaust void my warranty?
By now, your 7.3 Powerstroke is no longer covered by a factory warranty. However, if you have a third-party warranty on your truck, the new exhaust wouldn’t cause any issues unless it actually led to damage that you are trying to have repaired.
What are the most common 7.3 Powerstroke problems?
The 7.3 Powerstroke is much more reliable than the 6.0L. However, there have still been some complaints, such as a camshaft position sensor failure, leaking turbocharger pipes, an overheating engine and a cracked fuel filter.
Conclusion
It’s not hard to find the best exhaust for a 7.3 Powerstroke engine if you do your research. With our top picks, you can increase efficiency and gain better performance from your Ford Super Duty truck.
Here’s a recap of our top 4 exhausts:
- Inlet: 4" inner diameter - Outlet: 4" inner diameter - Overall Length: 30" - Body length: 24" - Body type: 7" round - style: Both ends can be inlet, no inlet or outlet difference.
- 100% welded design for long-lasting durability
- Stainless steel construction for lifelong protection
- CRF (Continuous Roving Fiberglass) technology absorbs unwanted interior resonance
- Upower Exhaust Tip: Before purchasing, please make sure the Brand Logo is "Upower".
