6.4 Power Stroke Power Guide: Stage 1 and 2 (2008-2010) | Alligator Performance

The 6.4L Power Stroke makes strong power from its twin turbos, and it has plenty more to give. With the particulate filter, EGR and factory emissions equipment kept in place, the legal path to more power is a tuner covered by a CARB EO, better airflow and cooling, and a transmission ready for the extra torque. This guide lays out Stage 1 and Stage 2, each with a towing build and a max power build.

Every card shows the fitment as it appears on the product page, and parts listed with a CARB Executive Order carry a green badge with the EO number.

Quick answer: the best power upgrades for your truck

2008-2010

Fix the radiator, up-pipes and fuel dilution issues first.
Stage 1 towing: Edge Evolution CTS3 plus an aFe intake.
Stage 1 max power: add a DPF-back exhaust and an aFe intercooler.
Stage 2: a FASS lift pump and a built 5R110W.

Before you add power

Start with a healthy truck. Check the radiator end tanks, look for up-pipe leaks, and keep oil changes short: regenerations wash fuel into the oil, and a tuned truck that tows needs clean oil even more. Make sure the truck completes its regenerations.

Tuning and some performance parts can affect your factory powertrain warranty. Check before you install.

2008-2010

Start with a healthy truck: work through the 2008-2010 maintenance guide first.

Stock power and where the limits are

Every number below is a factory rating at the crank or a typical figure at the wheels, as noted. "Reliable towing target" is where we suggest a truck that tows stops, so the engine, transmission and cooling system all live a long time.

Years	Stock rating	Transmissions	Reliable towing target	First limit you hit
2008-2010	350 hp, 650 lb-ft	5R110W automatic, ZF6 6-speed manual	About 75-90 hp over stock with a built transmission	The 5R110W, then cooling

Stage 1: bolt-ons and tuning

Stage 1 is the bolt-on step: tuning (where a legal option exists), better airflow and the gauges to watch what the engine is doing. The towing build is what we recommend for most trucks. The max power build adds the parts that let the same truck make more power without giving up reliability.

2008-2010

The Edge Evolution CTS3 is covered by CARB EO D-802-13 for 2008-2010 6.4L trucks. In testing for an earlier Edge programmer (CARB EO D-541-18), CARB recorded a 75 hp gain on a 2008 F-350, and Edge rates its top level at up to about 88 hp. The CTS3 also monitors exhaust temperature and particulate filter status. Add an intake listed with an EO and a DPF-back exhaust.

Stage 1 towing build

Best for most trucks that tow.

Towing pick

Edge 85400-100 CTS3 Diesel Evolution Programmer

Edge Evolution CTS3 programmer and monitor. Run a towing level when hooked up.

Listed with CARB EO D-802-13

Listed fitment: 1994-2019 Ford F250/F350 7.3L/6.0L/6.4L/6.7L Powerstroke

Check price and fitment

aFe Power 50-73004 Momentum HD Cold Air Intake System with Pro 10R Filter

aFe Momentum HD intake with an oiled Pro 10R filter.

Listed with CARB EO D-550-24

Listed fitment: 2008-2010 Ford F250/F350 6.4L Powerstroke

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Stage 1 max power build

Adds to the towing build for more power.

MBRP S6282PLM Tour Profile 4" Inch DPF-Back Exhaust Single Side Exit (Polished)

MBRP 4 inch DPF-back exhaust, polished.

Listed fitment: 2008-2010 Ford Super Duty F250/F350/F450

Check price and fitment

aFe 46-20071 BladeRunner GT Series Intercooler

aFe BladeRunner GT intercooler. Cooler intake air and lower exhaust temperatures under load. F-350 owners: confirm EO coverage on the product page.

Listed with CARB EO D-550-7

Listed fitment: 2008-2010 Ford F250/F350 6.4L Powerstroke

Check price and fitment

Stage 2: fuel, turbo and the parts that support them

Stage 2 adds fuel supply and airflow, and the supporting parts that keep the extra power reliable. On most trucks the transmission has to be part of Stage 2, so it is included here.

2008-2010

The emissions-legal Stage 2 on a 6.4 is about supply and heat, not big turbos or injectors: we do not carry any turbo or injector upgrade for the 6.4 that is covered by a CARB EO. A filtered lift pump protects the high pressure pump, and a built 5R110W holds the added torque while towing.

Stage 2 towing build

Fuel supply and drivetrain first.

Towing pick

FASS TSF16100G Titanium Signature Series 100GPH Fuel Lift Pump

FASS 100 gph lift pump with filtration and water separation.

No CARB EO: not legal for sale or use in California

Listed fitment: 2008-2010 Ford F250/F350 6.4L Powerstroke

Check price and fitment

ATS 309-914-3326 Stage 1 5R110 Package

ATS Stage 1 5R110W transmission package. Comes in 2WD and 4WD versions; match it to your truck.

Listed fitment: 2007.5-2010 Ford F250/F350 Powerstroke 4WD

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Stage 2 max power build

Adds to the towing build for more power.

FASS TSF16165G Titanium Signature Series 165GPH Fuel Lift Pump

FASS 165 gph lift pump for more supply headroom.

No CARB EO: not legal for sale or use in California

Listed fitment: 2008-2010 Ford F250/F350 6.4L Powerstroke

Check price and fitment

Transmission and clutch

2008-2010

The 5R110W can live around 500 hp if maintained and kept cool. Heavy towing at Stage 1 power is where a converter and build pay off. ZF6 manual trucks need a stronger clutch.

Valair NMU70432-01 HD Organic Clutch with Flywheel Rated at 400HP

Valair HD organic clutch with flywheel for ZF6 trucks. Rated at 400 hp, so it suits stock to mild Stage 1 only.

Listed fitment: 2003-2010 Ford 6.0L/6.4L Powerstroke

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Safe towing temperatures

Added power means added heat. These are the numbers to watch on your gauges while towing. They are sustained readings, not short spikes on a hill.

Reading	Normal while towing	When to act
EGT (probe before the turbo)	Under about 1,200°F sustained	Back off or downshift if it stays above 1,250°F. On trucks with a particulate filter, sustained heat above that risks the filter.
EGT (probe after the turbo)	Reads about 200-300°F lower than a pre-turbo probe	Know which probe your gauge uses before you set an alarm.
Transmission fluid	170-200°F	Act at 210-225°F sustained: slow down, downshift, add cooling.
Coolant	195-220°F	Act if it stays over 225°F.
Engine oil	210-240°F	Act at 250°F or more, sustained.

Emissions and legal fitment

Every part in this guide keeps your truck's factory emissions equipment in place and working. Where a part is listed with a California Air Resources Board Executive Order (CARB EO), the card says so. That EO exempts the part from California's tampering law (Vehicle Code 27156) for the vehicles it lists. An EO covers only the exact part numbers, years and engines it lists, and an EO for a tuner covers only the maker's preloaded tunes: a custom tune is not covered. Each EO covers its part by itself; CARB has not evaluated combinations of tuned parts. Parts marked "No CARB EO" are not legal for sale or use in California on pollution-controlled vehicles. Exhaust that bolts on behind the catalytic converter or particulate filter generally does not need an EO, but local noise rules still apply.

2008-2010

The 6.4 has EGR with two coolers, an oxidation catalyst and a particulate filter. Keep all of it. The DPF-back exhaust bolts on behind the filter. The Edge CTS3 is covered by CARB EO D-802-13 with its preloaded tunes.

Shop parts for your truck

Shop all 2008-2010 parts and accessories

Not sure which parts your truck needs?

Alligator's sales team helps 6.4 Power Stroke owners plan power and reliability upgrades every day. Tell us your year, mileage and what you tow, and we will build a parts list that fits.

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