Just a hair over 600 miles since the last smog test in 2011. Not sure how I accumulated that many.

 

Holy jeeze, your gonna wear that 7.3 right out!

 

I have found something in App G. What is "exhaust after treatment system." Found on G6. Having a problem because I have 3 1/2 pipe from the turbo to the cat instead of the original 3 inch.

 

Exhaust After Treatment Systems in diesels has been an evolving term, as the available emissions control technology has evolved very rapidly over the last 10 years.

In the post 2007 world, diesel exhaust after treatment systems are diesel particulate filters (DPF), diesel oxidation catalysts (DOC), selective catalytic reduction systems (SCRS), and additives such as DEF that are part of those systems.

Because you are posting in the 99-03 forum, I suspect you have an earlier, simpler CAT.
But by legal definition, that cat would still fall under the DOC category, and is a regulated item.

Modifications are exempt CAT back, but not in between the turbo and the CAT, unless an EO has been issued on the part or system that you are running.

For example, I am running a 3.5" DP, but my DP has a valid Executive Order Exemption, because the manufacturer of my DP spent the extra bucks to have the part validated to prove that a 3.5" hole isn't going to pollute any more than a 3" hole.

If you know the brand of your 3.5" DP, who knows, there might be an EO on file for it.
But I think there are only 3 manufacturers in the aftermarket performance space that were wise enough back then to follow the rules. Now, everyone has to follow the rules, but the newer players aren't retroactively paying to have old parts to old trucks validated.

What brand DP do you have?

 

I have a 2004, made in June 2004. Had a muffler shop put on my exhaust system in 2005. It now has 3.5 " down to 4", 4" to a four bolt flange, CAT is bolted to the flange (2004 Cat was bolted on). There was only one exhaust system for 2005. The shop I think used a Banks. Have to see if I have any paper work. We did not know much about the smog stuff in 2005. If I do not have any paper work what could be my next step. Also sry I am in the wrong post. This truck passed smog in 2011. The place went out of business and I am having trouble with the new place. Can of sorta stress out a little now. Thank you for the help.

 

If your DP is a Banks, you're golden. Banks was the first aftermarket "performance" diesel exhaust system manufacturer to register most of his core products with the EPA and CARB, and obtain Executive Orders exempting these core products from equipment failures at smog checks.

He did this TEN YEARS BEFORE smog checks would even be required, all the way back in 2000. There. I said it. But I didn't bring his name up first. People dismiss Banks products as being over priced, but it costs money to jump through these hoops of red tape and regulation... money that many other aftermarket companies weren't willing to spend. Or didn't have.

It also costs money to stay in business... and many a competing company has come and gone while Banks remains in business. Nuff said.

Banks registered the components and calibrations for his Stinger Kit, his Git Kit, and his PowerPack systems with the CARB, and obtained Executive Orders for them. Now, if you have a Big Hoss or a Six Gun, then no, that isn't on the exempted list.

What to do?

First, try very hard to find your receipt and/or paperwork.

Second, try sending an email to Banks. You can try calling to, but I think his sales reps are still commissioned based, and, well, those aren't the kind of conversations I like to wade through.

Third, the Executive Orders are public record, so a quick search online of the following terms combined together should produce for you an idea of what specific Banks Part Numbers have the Executive Order for your specific model year and Ford PCM engine calibration:

C.A.R.B. Executive Order Gale Banks 2004 Ford Super Duty .pdf

I add the .pdf term in the search engine to avert a lot of the dollar driven links that fill up the first few pages of results. What you are looking for will be on a .pdf.

Finally, I understand your stress. I really like smog controls, but I very much dislike the way smog checks are administered by private one man fiefdoms who are king for a day over whether or not you can register your vehicle.

One of the advantages that diesels used to have was an exemption from these calls before the service station throne, thereby completely avoiding the frustrating subjection to the "interpretations" of the regulations by a newly minted smog check licensee who didn't study law and didn't speak a word of English the previous year.

That, combined with the cost of diesel doubling since 2004, is a double whammy hit that I'm sure you didn't anticipate back when you bought your 6.0. Never mind the worries about the 6.0. But hang tight... you are already miles ahead of the game.

As soon as I saw App. G in your first post, I knew you weren't going to be taken down without a good fight. So get that paperwork, either from your own files, or from this:

Ask Banks where the Part Number is stamped on the DP. Most of his parts have part numbers etched on them. I'm sure my DP (yes, a Banks) has a part number (but I have all my paperwork, so I'm not crawling), because I've noticed that all of my other Banks parts have part numbers on them.

When you are given the location of where the part number is, get your mirror and small digital camera, and photograph that part number.

Then, print the photograph and the .pdf files you obtained with the Executive Order, and present that to your king for the day. If he scoffs at that evidence of exemption and compliance, then it is time to cut the legs off of his grease covered throne and step it up to a B.A.R. Smog Referree.

I had to do that once with an old Jag that I had 30 odd years ago. The system works. So work the system.

 

Going to see the referee on Friday. Mine appears to be a Flow Pro 524. See what happens.