I have a F-250 with a 460 CID and a 5 speed in it, I'm looking into bypassing all the emissions crap and wanted to see if anyone could tell me what what all would be involved and what kind of MPG I might pick up in doing so. I'm also open to any other tips for picking up any extra MPG! Thanks!
Removing what little smog equipment there is won't have any positive effect on fuel milage and may even hurt it a bit if you disable EGR. What axle gear ratio does the truck have? If it's not used for heavy towing then a swap to 3.55 gears(assuming you now have 4.10s) would be the best thing you could do.
You'll see no increase in MPGs. I've removed the A.I.R. pump, the catalytic converter, and all of the associated lines, and I saw no difference except one less tube to reach around while working on the engine.
Unless your EGR isn't functioning for some reason, leave it alone. It actually helps you achieve higher fuel mileage.