The MBRP S6206409 (Armor Plus / XP Series) is a heavy-duty 4-inch turbo-back single-exit exhaust system engineered for 2003–2007 Ford F-250 and F-350 Super Duty trucks equipped with the 6.0L Powerstroke diesel engine. Constructed from 100% durable 16-gauge T409 stainless steel tubing, this system provides superior corrosion resistance against road salt, tar, and harsh weather conditions compared to standard aluminized steel. MBRP equips this system with a 3.5-inch to 4-inch two-piece mandrel-bent turbo downpipe, intermediate piping configured to retain the factory catalytic converter, a high-flow chambered performance muffler, OE-style welded hangers, and a mirror-polished 5-inch angle-cut T304 stainless steel exhaust tip.

High exhaust gas temperatures (EGTs) while towing heavy trailers, severe turbo backpressure caused by the flattened factory stamped downpipe and dense OEM baffle muffler, sluggish low-end turbo spool, and rust-through corrosion from winter road brine are what this system eliminates. The factory Ford 6.0L exhaust traps intense thermal energy directly behind the variable geometry turbocharger (VGT), driving up engine bay and cylinder head temperatures under load. The MBRP S6206409 opens up exhaust pathways to drop peak EGTs by up to 100–200°F, reducing backpressure on the turbine wheel, enhancing throttle response, and delivering MBRP's signature deep "Street Profile" exhaust note without obnoxious highway in-cab drone. It is a complete 4-inch turbo-back exhaust kit including the downpipe, catalytic converter adapter pipes, performance muffler, over-axle pipe, tailpipe, 5-inch polished tip, and band clamps; catalytic converter delete pipes are sold separately.

It fits 2003–2007 Ford F-250 and F-350 Super Duty pickup trucks equipped with the 6.0L Powerstroke diesel engine across SuperCab (Extended Cab) and Crew Cab configurations with 6'9" Short Beds or 8' Long Beds that retain the factory catalytic converter (does not fit Regular Cab models, Cab & Chassis configurations, or Ford Excursions).

Fitment

• 1999.5–2003 / 2003–2007 Ford F-250 Super Duty 6.0L Powerstroke (SuperCab & Crew Cab; Short & Long Bed)
• 2003–2007 Ford F-350 Super Duty 6.0L Powerstroke (SuperCab & Crew Cab; Short & Long Bed)
• Fits Single Rear Wheel (SRW) and Dual Rear Wheel (DRW) pickup configurations
• Complete 4-inch turbo-back replacement exhaust system (retains factory catalytic converter)
• Includes mandrel-bent 3.5" to 4" two-piece downpipe for clearance and flow velocity
• Fabricated from 16-gauge T409 stainless steel for lasting rust and corrosion resistance
• High-flow chambered performance muffler lowers EGTs while delivering a rich, mellow street tone
• Includes premium 5-inch single-wall angle-cut mirror-polished T304 stainless steel exhaust tip
• OE-style welded hangers install directly into factory chassis rubber isolators
• Complete exhaust system kit including heavy-duty band clamps and hardware

Support the vehicle securely on a lift or heavy-duty jack stands and disconnect both negative battery cables. Spray penetrating lubricant onto all factory rubber isolator hangers, the catalytic converter flange bolts, and the turbo downpipe V-band clamp behind the turbo turbine outlet. Cut the factory downpipe using a reciprocating saw to facilitate removal from under the truck, then loosen the factory V-band clamp to extract the upper downpipe section from the engine bay. Unbolt the catalytic converter from the factory exhaust, unhook the rubber hangers, and lower the original intermediate pipe, muffler, and tailpipe assembly out from under the truck. Install the upper section of the MBRP two-piece downpipe onto the turbo turbine discharge flange, loosely securing the factory V-band clamp before joining the lower downpipe section. Reinstall the factory catalytic converter to the MBRP downpipe adapter, attach the intermediate extension pipe (trimmed to length according to cab and bed size per instructions), and slide the chambered performance muffler into place. Guide the over-axle and tailpipe sections over the rear axle housing, inserting the welded hangers directly into the OEM rubber mounts. Install the 5-inch polished T304 stainless tip onto the tailpipe exit behind the passenger rear tire, adjust all joints to maintain a minimum of 1 inch of clearance around brake lines, shock absorbers, and spare tire shielding, and torque all heavy-duty band clamps from the turbo back to 35–40 ft-lbs.