Introduction If you own a 2023–2026 Ford 6.7L Power Stroke and you’re tired of DEF refills, DPF regen cycles, and EGR soot buildup, a full emissions delete is one of the most discussed upgrades in the...

Introduction

If you own a 2023–2026 Ford 6.7L Power Stroke and you're looking to understand how a full emissions delete is performed on an off-road-only truck, this guide walks through the complete mechanical and tuning process. It is based on a real shop-floor demonstration covering the ECU flash with an Easy Link Auto Agent, EGR cooler removal, DPF/SCR exhaust drop, and installation of a full 5-inch delete exhaust.

⚠️ OFF-ROAD USE ONLY: Emissions deletes are illegal for on-road use in the United States and in many other jurisdictions. This write-up is for educational and off-road/competition purposes only. Operating a deleted vehicle on public roads carries serious legal, financial, and safety risks. Always check your local laws before modifying emissions equipment.

The procedure below is based on a 30-minute hands-on video using a Diesel Dudes delete kit (EGR delete, exhaust, and Easy Link tuner). While the demonstration covers 2023–2026 trucks, the same general principles apply to other 6.7L Power Stroke builds. If you need an EGR delete kit for 2011–2019 6.7L Power Stroke models, iFJF offers a verified bolt-on kit — also for off-road use only.

Tools & Parts Needed

Item	Notes
DPF/DEF/EGR delete kit	EGR cooler delete hardware, blocker plates, exhaust system, tuner (e.g., Diesel Dudes kit)
Easy Link Auto Agent + app	Used to flash the off-road tune and clear codes
Battery charger	5–10 amp setting; keep batteries alive during flashing
Metric socket set	7 mm, 10 mm, 13 mm, 15 mm, 21 mm sockets and ratchets
Extensions and swivel socket	Long 1/4" extension with swivel for back EGR bolts
Pry bar / exhaust hanger pliers	For rubber exhaust hangers and separating flanges
7 mm nut driver	For air intake piping bolts
Pick / small screwdriver	For unlocking red connector tabs
Electrical tape and zip ties	To seal and secure unplugged sensors
Clean drain pan	Coolant will be reused
Exhaust lubricant / penetrating oil	For rubber hangers and exhaust clamps
Lift or ramps	Makes exhaust work much easier and safer

Step 1: Flash the Truck First with Easy Link

On 2023–2026 6.7L Power Strokes, the ECM must be tuned before any physical hardware is removed. At the time of the source video, only one off-road tune was available for these trucks, which makes the process straightforward.

1. Connect the battery charger to the batteries and set it to 5–10 amps. A low-voltage condition during flashing can brick the module.
2. Plug the Easy Link Auto Agent into the factory OBD-II port under the dash. Do not use a splitter or piggyback harness.
3. Download the Easy Link Auto Agent app on your phone, connect to the Auto Agent Wi-Fi network, then open the app.
4. Turn the key to RUN but do not start the engine.
5. Hit Link when the app prompts, then Accept and continue. Enter "delete done" when asked.
6. Open the menu → Vehicle → ECU Profiles and select the tune that matches your truck (e.g., High Output). Read the profile description carefully: it will note that the throttle valve must stay plugged in and the EGR temperature sensor must be unplugged.
7. Download the tune from the cloud icon, then tap Install → Proceed.
8. Follow the key-cycle prompts: turn key off, continue, turn key to RUN, continue. The dash may go black and show warnings—this is normal. Do not touch anything until the progress reaches 100%.
9. After the flash completes, use the app's DTC menu to scan and clear any codes that appeared during the process.

Warning: Do not change the tire size in the Easy Link app. Users report it throws an error code. Leave the tire size stock.

Step 2: Unplug the Required Under-Hood Sensors

Before the engine is started, you need to unplug three key connectors:

1. EGR valve connector — Slide the red locking tab back, then pull the connector off.
2. EGR vacuum pump / small vacuum solenoid — Unplug the small connector.
3. EGR temperature sensor — This is the most critical one. It must remain unplugged with this tune. It is tricky to reach, so remove the black plastic air intake piping (7 mm nut driver) to gain access. Follow the wire to its connector, unlock the red tab, and unplug it.

Wrap each open connector with electrical tape and zip-tie them away from the fan and belts. For older trucks, plug kits are available; for 2023+ models, they had not yet been released at the time of the video.

Step 3: EGR Cooler Delete

Although the exhaust can technically be left on with the tune, the 2023+ trucks have a particulate filter built into the downpipe that must be removed. The EGR cooler is removed first because it gives better access to the downpipe clamp.

1. Drain the coolant. Locate the driver-side coolant reservoir drain plug underneath the truck. Turn it about 180° total (a quarter turn, then pull and turn another quarter turn). Catch the coolant in a clean pan for reuse. Loosening the reservoir cap speeds draining.
2. Re-route the heater hoses. Loosen the two hose clamps on the small coolant lines going to the EGR cooler, then join those hoses together using an existing hose clamp. This bypasses the EGR cooler section.
3. Remove the air intake ducting. Unclip the air filter housing, remove any bolt or clip, and set it aside.
4. Remove the EGR cooler pipes. Remove the bolts on the intake and exhaust-side pipes. Save the factory gasket; it will be reused behind the blocker plate. Remove the pressure sensor before pulling the pipe, and plug the intake hole with a rag to prevent debris from falling in.
5. Install the intake blocker plate. Place the plate with its O-ring over the intake port and secure it using the OEM bolts.
6. Disconnect the remaining EGR cooler lines and wiring. Pop the vacuum line off, release the plastic clips holding the harness to the cooler, and free all wiring.
7. Remove the EGR cooler. Remove the seven bolts around the EGR cooler (three along each side, one in the middle). A long 1/4" extension with a swivel socket helps reach the back bolts. Gently pry the cooler free, move it left to clear the intake manifold, and lift it out. Set it in a drain pan to catch residual coolant. Be careful not to hit the alternator.
8. Install the exhaust manifold blocker plate. Use the provided Allen-head bolts with O-rings and snug them down. Do not over-tighten.
9. Cap the vacuum line. Pull the rubber 90° fitting off the plastic vacuum line, slide the supplied rubber cap over the end, and secure it with a small zip tie.

Step 4: DPF, DEF, and Full Exhaust Delete

With the EGR cooler out of the way, the exhaust can be removed. This is the heaviest part of the job and is much easier with a lift or ramps and a second set of hands.

1. Unplug all exhaust sensors. Work from the tailpipe forward. One rear sensor on the full exhaust requires dropping the spare tire to access its connector. If you are only installing delete pipes, that sensor can be left plugged in. Tape and secure all disconnected connectors.
2. Drop the spare tire if you are installing a full exhaust system.
3. Remove the tailpipe section. Spray the rubber hangers with lubricant, then use a pry bar or exhaust hanger pliers to pop them off.
4. Remove the DPF/SCR canister. Remove the three nuts on the flange behind the DPF, then pop the front rubber hangers. Lower the canister carefully.
5. Remove the transmission crossmember. Unclip the wiring on top, unhook the coolant lines, support the transfer case, and remove the four crossmember bolts. This gives room to drop the downpipe.
6. Remove the transfer case guard and the two 21 mm nuts on the downpipe studs.
7. Loosen the downpipe clamp. From the top of the engine bay, loosen the 15 mm downpipe clamp. Tap it with a screwdriver if it is stuck to the pipe.
8. Remove the factory turbo elbow. Unplug the exhaust back-pressure sensor for room, then loosen the V-band clamp at the turbo. Remove the bolt completely and pry the clamp apart. The elbow can be fed out from underneath.
9. Install the new turbo elbow and downpipe. Reinstall the studs into the cylinder head if you removed them. Slide the new turbo elbow into the V-band clamp at the turbo, but leave it loose enough to pivot. Slide the new downpipe over the elbow and onto the studs, then tighten the nuts while holding the downpipe centered. Tighten the V-band clamps from the top.
10. Install the new exhaust system. Assemble the sections from front to back, starting at the downpipe flange and working toward the tailpipe. On full 5-inch systems with a fifth-wheel plate, you may need to dent the pipe slightly where it contacts the hitch plate. Tighten all clamps from front to back.

Step 5: Reinstall Coolant and Button Up

1. Reinstall the transmission crossmember and transfer case guard.
2. Reinstall the air intake piping and air filter housing.
3. Reconnect any coolant hoses and secure them with the factory clamps.
4. Zip-tie all unplugged sensors and capped lines out of the way of the fan and belts.
5. Reinstall the coolant drain plug and refill the coolant.
6. Start the truck and check for exhaust leaks, coolant leaks, and proper throttle response.
7. Scan for codes one last time and clear anything that is not persistent.

Pro Tips

Tip	Why It Matters
Always flash the tune before turning a wrench on emissions hardware.	Starting or moving the truck with missing sensors can throw hard codes that complicate the flash.
Keep a battery charger connected during the tune.	A voltage drop mid-flash can corrupt the ECU.
Label and tape every unplugged connector immediately.	Prevents fan/belt damage and keeps the engine bay tidy.
Use a second person when dropping the DPF/SCR canister.	The assembly is heavy and awkward; an extra set of hands prevents injury and damage.
Do not over-tighten EGR blocker-plate bolts.	Small Allen bolts and O-rings only need to be snug; over-tightening can distort the plate or strip threads.
Reinstall removed downpipe studs before mounting the new downpipe.	The new downpipe slides over the studs, so they must be in the head first.

Parts Cross-Reference

Component	Brand	Fitment / Notes
EGR Delete Kit	iFJF	2011–2019 Ford 6.7L Power Stroke F-250/F-350/F-450/F-550 — Off-Road Use Only
Full 5" Delete Exhaust	Diesel Dudes	2023–2026 6.7L Power Stroke (as shown in source video)
EGR Delete Kit	Diesel Dudes	2023–2026 6.7L Power Stroke
Easy Link Auto Agent	Easy Link	Tuner and code reader for supported Power Stroke models

FAQ

Do I have to tune the truck before installing EGR/DPF delete hardware?

Yes. On 2023–2026 6.7L Power Strokes, the ECU must be flashed with an off-road tune before the emissions sensors are unplugged. Starting the truck without a tune will trigger limp mode and a lit dashboard.

Can I leave the EGR cooler on the truck and just unplug it?

With the tune used in this guide, the EGR temperature sensor must be unplugged, but the cooler could theoretically stay installed. However, because the 2023+ downpipe has a built-in filter that must be removed, the EGR cooler is typically removed first to gain access to the downpipe clamp.

Why do I need to drop the spare tire?

Only if you are installing a full exhaust system. One of the rear exhaust sensors is routed between the frame and the spare tire, and the connector cannot be reached otherwise. If you install only delete/race pipes, that sensor can usually stay connected.

Can I reuse the factory coolant?

Yes, as long as you drain it into a clean pan and no debris gets in. After the first drive, check the coolant level again; the thermostat may open and the level can drop.

Is this legal for street use?

No. Removing or disabling emissions equipment is illegal for on-road vehicles in the United States. Under the Clean Air Act (42 U.S.C. § 7522), tampering with emissions controls is a federal violation. The EPA can impose fines of up to $4,819 per defeat device. A deleted truck will not pass state emissions inspections, may void your warranty, and could cause your insurance provider to deny coverage in the event of an accident. This guide is intended exclusively for off-road, competition, or closed-course vehicles. Always follow local laws and regulations.

What are the risks of an emissions delete?

Key risks include: (1) ECU damage — a voltage drop during tuning can brick the engine control module; (2) Engine/turbo wear — improper tuning can cause turbo overspeed and excessive EGT; (3) Warranty void — Ford and most dealerships will void coverage on related components; (4) Resale issues — many dealers and buyers refuse deleted trucks; (5) Legal penalties — fines, registration denial, and in some cases vehicle impoundment. This is not a modification to take lightly.

Conclusion

A full DPF/DEF/EGR delete on a 2023–2026 6.7L Power Stroke is a significant mechanical undertaking. It requires methodical planning, the right kit, a reliable tuner, and a clear understanding of the legal and mechanical risks involved. Flash first, then remove the EGR cooler, then drop the exhaust, and finish by reinstalling the coolant and checking for leaks. Whether you are working on a 2023+ truck or an earlier 6.7L model, using quality bolt-on hardware like the iFJF EGR delete kit makes the job cleaner and more reliable.

⚠️ REMINDER: This content is for OFF-ROAD / COMPETITION USE ONLY. Do not operate a deleted vehicle on public roads.

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