So you bought a Ford Super Duty with a Powerstroke turbo diesel and want to get more power out of it. Maybe even increase fuel mileage just a little since fuel prices are always on the rise. You have a few options. In fact in many cases a combination of tricks can greatly increase performance as well as mileage. But to be honest, only certain combinations really work to their full potential. To know with any certainty whether or not a combination of products such as a power programmer, intake and exhaust, the three most popular diesel performance items, will work, they have to be tested. And that is precisely what we set out to do with this 2006 Ford Powerstroke, to find out just how much power we could wrench out of the popular Ford rattler.
But it should be said in this time of record high fuel prices, which includes diesel fuel too, fuel economy is becoming just as important as making more power. Generally when we talk about adding performance related products such as an air intake system, power programming modules or exhaust systems, we relate to the power increases from such products. Today we seek to not only discuss the increase in performance, but how these products can also increase the miles you can get out of a tank of fuel. This in turn means you get your performance fix while saving money every time you fill up your tank.
To address the issue of finding out just how to "hot rod" your diesel engine while providing a system which can increase fuel economy, the brains at Flowmaster Mufflers teamed up with K&N Engineering and Edge Products to put together what can be considered the "ultimate power package" for the big three diesel trucks. The trio of technical forces gathered at Flowmaster's R&D center in Hayden, Idaho where three 2006 model diesel trucks were tested. Those included the Dodge Cummins, Ford Powerstroke and Chevy Duramax. For this installation we will address the 2006 Ford Powerstroke Turbo Diesel.
Flowmaster built a very high-tech research facility that features the best testing equipment and dyno on the market. The goal was to document the installation of Flowmaster Muffler's American Thunder four-inch cat back exhaust system featuring the time-tested 50-series muffler (P/N 17377), along with a K&N AirCharger Performance Kit (P/N 63-2546-1) as well as the popular Edge Products 6.0L Powerstroke Juice & Attitude Power System (P/N EJF2000WAM). Each of these kits by themselves have proven to be extremely popular with consumers as well as each product by itself being capable of notable to substantial power and economy increases. The goal was to give the consumers cold, hard facts in terms of power enhancements if these three key ingredients were combined into a performance package.
In the following photos you will see how each kit was installed. This is the part of the article where we show you how you can install the products yourself should you feel the urge to do so. Each is really that easy to install. Prior to the installations the 2006 Ford Super Duty was tested on Flowmaster's SuperFlow dyno to get a baseline average of the stock Powerstroke power and torque figures. After several runs the average stock power was 248 hp/490 lb-ft torque. Max power achieved was 299hp/496 lb-ft. torque. After the installations of the Flowmaster American Thunder Exhaust System along with the K&N AirCharger Performance Kit and Edge 6.0L Powerstroke Juice & Attitude Power System the Ford was driven around town for a while to let the computer learn about its new products. Then the truck was secured back onto the SuperFlow dyno where more than a dozen test runs were made with the Edge Attitude "on the fly" adjustable power level was set to level 3 which is the most commonly used level by consumers.
After compiling the data the Average results from the runs produced an average of 305hp/596 lb.-ft torque, which translates into an increase of 57 horsepower and 106 lb.-ft torque! The maximum horsepower achieved was 363hp/626 lb.-ft torque, which translates to a 64 horsepower and 130 lb.-ft torque increase from the maximum baseline stock numbers. The dyno graph shown will give you a visual as to the power increase the Powerstroke delivered when benefiting from this new combination power package, the black lines showing the stock average baseline figures as compared to the red average power package figures. The dyno graph itself speaks volumes for the power increase this trio package produces.
But there is a catch. You could get better fuel mileage too! With more power available from the Powerstroke engine, that translates into the potential to save a lot of money on fuel since the engine is actually working more efficiently. There are plans for this kit to be marketed in the near future exclusively through several major retailers. After seeing the dyno runs in person, I hardly doubt you would be disappointed.
FLOWMASTER
For dealer information contact:
tech line: 800-544-4761
EDGE PRODUCTS
DEPT TEN
1080 South Depot Dr.
Ogden, UT 84404
888-360-3343
K&N FILTERS
PO Box 1329
DEPT TEN
1455 Citrus St.
Riverside, CA 92502
800-858-3333
 It is important to lead off with this installation by showing you the final dyno chart which illustrates the true performance gain using these three kits, and with the programmer set on #3 mode. Max power achieved was 363hp/626 lb.-ft torque over stock, an increase of 64 horsepower and 130-ft-lbs torque. With the programmer set to the highest mode, the increase in performance was much greater. |  First comes the removal of the stock air filter box and intake tube. The tube is two-piece and both sections must be removed. |  |
 With the factory rubber grommets removed from the canister holder, the new rubber mounted studs are installed into the two mounting holes. |  After assembling the intake bracket and saddle, the new mount is installed onto the 10mm valve cover bolt which holds the engine dip stick. |  Next, the provided edge trim is installed onto the inner tube hole on the heat shield as shown. Some trimming may be required. |
 With the two long brackets which are used to mount the shield to the factory air canister saddle, the shield is installed and the brackets secured to the previously installed bolts. |  The factory mass air sensor is removed from the stock air tube and a new adhesive gasket applied to the back side. A new port for the mass air sensor is provided in the K&N tube allowing the sensor to screw in place just as it did on the factory tube. |  |
 In addition, the factory air restriction gauge is installed into the provided port. |  Though it is difficult to see from this angle and the tight quarters of the engine compartment, the next step is to install the K&N turbo inlet tube along with the rubber coupler. The coupler assembly locates over the previously installed saddle bracket and will be permanently tightened later. |  Next comes the installation of the outer intake tube through the inlet hole on the heat shield and up to the coupler where the connection is secured to the saddle mount using the provided hose clamps. |
 |  With the tube assembly installed, the K&N AirCharger filter is placed inside the heat shield and connected to the intake tube. |  A provided bracket is used at the front of the air filter and connects to the radiator mount stud as shown. Final tightening of the filter-to-intake tube coupler is done along with checking the tightness of the entire assembly. |
 |  STEP TWO: INSTALLING THE FLOWMASTER "AMERICAN THUNDER" CAT BACK EXHAUST SYSTEM--Here is a look at the Flowmaster 2003-06 Ford F250/350 6.0L turbo diesel exhaust system. The "American Thunder" kit includes four-inch tubing and a Flowmaster 50-series muffler along with a five-inch stainless steel tip. Note: the catalytic converter is from the truck. In states which require the cat, it is important that it is re-installed. |  Step one was to begin disassembly of the factory exhaust using a trusty electric saw. |
 The first cut is to remove the tail pipe from the factory trash can-size muffler. |  At the front of the exhaust the connection in front of the catalytic converter is unbolted. |  With a couple of helping hands, the factory exhaust is removed pretty much intact. Remember the factory cat will be reinstalled so it will have to be removed from the factory exhaust. |
 Factory turbo outlet pipe that extends down past the firewall and bending to the cat is one-piece and extremely difficult to remove in intact. The solution is to simply cut the tube at the bend below the firewall, then remove both sections. |  The new Flowmaster turbo outlet pipe is installed from the bottom of the truck. It should also be noted that due to the extra width of the pipe the pipe has to be pressed through the small space between the engine and firewall insulation. |  Once in place, the new tube is secured to the turbo outlet as shown. |
 Using several locking stands the turbo tube is connected to the cat extension tube and temporarily held in place. |  We then move to the rear where the tail pipe section is secured to the factory hangers while the Flowmaster muffler is slid onto the pipe. |  The reason for doing it this way is because this kit comes with the center pipe which connects the cat to the muffler in a length suited for long bed Super Duty trucks. For short bed models, the center section must be measured and cut to fit. |
 Since this truck is a short bed model, here we can see the how the tubing is too long for the assembly to fit together properly. |  A measurement is taken, keeping the necessary overlap for the connectors in mind, then the center section is cut to meet this requirement. |  Once cut, the center section is installed onto the exit port of the catalytic converter. |
 With knowledge that the center connector pipe is cut to the proper length, the entire Flowmaster exhaust system is assembled while checking to make sure everything lines up properly before the assembly is buttoned up. |  Flowmaster provides these trick threaded clamps for each union point which provide a good seal when tightened up. |  Last on the exhaust list is to install the five-inch the stainless steel tip onto the tailpipe for clean, custom appearance. |
 STEP THREE: PLUGGING INTO POWER WITH THE EDGE JUICE MODULE--To maximize this venture, the decision was made to use the Edge Products Juice w/Attitude power module which provides five different adjustable power levels along with a turbo timer, cold engine protection, trouble code analysis, along with numerous real-time readings including EGT, boost, tranny temp and a long list of other features that basically replace your stock gauges while providing the opportunity to fully tap into the power potential of the 6.0L Ford Powerstroke turbo diesel motor. |  First step in the Edge Juice Module installation is to locate the PCM connectors on the driver's side fender next to the battery. The two PCM connectors closest to the cab are removed. |  The two Edge PCM cables are then installed into the PCM module with the one with the blue band located in the center port. Then install the factory PCM connectors that were removed from the PCM and install them into the corresponding Edge PCM connectors, again with the blue banded one attaching to the factory connector that plugged into the middle of the PCM. |
 The dual pig tail wires with a single connector are then inserted into the Edge module. |  Next we ran the wires for the Edge Attitude programmer through the firewall, with the engine compartment connectors attached to the wires extending from the Juice module. |  To finish off the under-hood installation, the Juice module is mounted with Velcro to the fuse box cover. |
 The easiest way to route the Attitude wires into the interior is to run them through the inner fender, then with the door open, into the cab and through the A-pillar cover. |  Using the provided mounting bracket, the Edge Attitude programmer is mounted to the dash next to the A-pillar. |  After taking the truck out for a drive to get the drivetrain up to normal operating temperatures, the Ford was strapped down to Flowmaster's SuperFlow dyno where final testing of the proposed new combination power package could be verified. |
 Here Lee from Flowmaster is seen making numerous dyno runs while monitoring all aspects of the truck to make sure there are no loopholes which would skew the results. In the end, and with the Edge programmer set on #3 mode, the new power package saw a max increase of 64 horsepower and 130-ft-lbs torque from stock. Those are real numbers under as close to real conditions as you can expect. | | |
