Guys I cannot thank you enough for all the input, seriously thank you!

Yeah i'm going with the AFE 7, seems to be the intake of choice so if it ain't broke dont fix it.

I'd be really interested to see your MPG on your truck, be safe on your trip!

So here's a thought??

Why not make a retro-kit for the 6.4 to use urea, a tune to fix the timing and still pass emmissions? Maybe I'm just nuts, but seems like that would be a good game play no?

I've also notice on my truck (highway) the sweetspot isn't necessarilly speed, but rather the RPM between 1500-1750 (right about 65mph in my case, dont know what gears i have) as far as MPG is concerned.

I did do some research since it finally cooled off down here at the bottom of Texas, yeah I can drive 20 min straight south and be in Mexico. Noticed some "white smoke / vapor" at the tailpipe, after researching my rig has the original intercooler and is a job1 truck so it was before the TSB for newer intercooler. Gonna put the purge valve on it this week, probably water in it.

Again everyone thank you so much for all the help, you guys have been great!

My final conculsion:
Spartan Tuner, probably 210 or 250 tune
AFE 7 intake
4" Exause from the downpipe out w/DPF & CAT delete

Next step:
CAC Pipe upgrade, man Ford put a nasty kink in that pipe!

 

Some guys, at least with the 6.0L, pass emissions inspections with a tune and straight piped exhaust. Some tests are only visual, others do opacity checks. I don't think anyone measures NOx emissions, so urea would be a waste of time.

 

I wanted to update everyone as to the progress with the issues on my truck.

Had the radiator replaced, had a leak.

While at the dealer (thank goodness i bought the extended warranty) they replaced the following:

Radiator
Timing cover gaskets
Rear main seal
Turbo assembly gaskets (white smoke issue)
Injection Pump

What a list huh?

DPF is still bad, but ext. warranty wouldn't cover and I'm ordering the Spartan setup and such in the next day or so, so no big deal.

Planned mods:
Spartan
4" exuast DPF/CAT delete, downpipe out
AFE7 intake kit
Adding a bleed valve to the intercooler for draining water

I'm also trying to find a way to upgrade the radio to the new Sync setup for the truck, not sure if its even possible though, any ideas?? Or at least find the part numbers for the NAVI available for that year truck since it should be a direct fit.

Thanks again for all the help guys!

 

So how many miles on this truck. DPF is an emissions component. Covered to I think 60K miles.

 

Truck has 118k lol just a few miles...concerned bout blowby now noticed the tube from oil filler to intake broke and white smoke need to do cap test to see how bad.

 

Ok guys any thoughts on this?? I noticed a smell in the cabin, when I checked under the hood the host connecting the oil filler to the intake was loose and broke so hence the smell, but even at that I took the cap off and wow looked really abnormal to me. I took a quick video with my phone and put it on my servers here at the house if you want to see what it looks like, but seems like blowby to me or maybe the turbo seals not set right after the replacement??

http://www.radserver.net/blowby.avi

See what you guys think?

 

I thought emissions was 120-150k for some reason...

 

I can't speak for others but I am def running nothing but Spartan. They were the best when I was running them in my 6.0 and, I personally feel they are the best in my 6.4. I am so unbelievably impressed with this truck tuned. I am currently running the 275hp tune on my truck and I couldnt be happier. The truck locks up so early, and then you are gone! Right now I have my 900lbs plow on the front, and 1000lbs in the bed and I still have the 275 in place. I can't believe how this truck doesn't even sweat doing this. All of the safety cut offs aren't even close to being crossed yet.... I still can't believe it.

Spartan hands down