MAHLE Motorsport Introduces New PowerPak Piston Sets

Counterman · February 7, 2023

MAHLE Motorsport announced four new performance cast PowerPak piston sets for the 6-liter and 6.4-liter Ford Powerstroke.

Developed in direct response to consumer demand for diesel motorsports competition, the new 6-liter pistons are based on the 2004+ design, and the 6.4-liter pistons are based on the MaxxForce design that provides maximum strength and superior durability, according to the company.

“All four sets offer incredible versatility, allowing a daily driver to become a weekend warrior for drag, dyno or pulling competitions,” the company added.

The castings retain the OEM steel top ring insert for the longevity of the top ring groove and are engineered with fully radiused valve pockets to reduce stress and fatigue cracking. Also, a lower compression ratio (.5 to 1.5 points) allows more flexibility for high-output tuning.

They’re designed with performance bowls that reduce erosion issues caused by high pressure, long duration and advanced injection timing, and available with 0.100-inch-deep intake and exhaust valve pockets that work with many performance aftermarket camshafts.

The 6-liter PowerPak set is cast from MAHLE’s proprietary M124 alloy and the 6.4-liter Powerstroke set is cast from M142 alloy. Both are designed for a 4.134 stroke and 6.929 rod. The CR is calculated with 0.0008-inch piston protrusion above deck and 0.059-inch head-gasket thickness.

As with all PowerPak piston sets, the pistons are treated with MAHLE’s proprietary GRAFAL skirt coating for reduced drag and increased scuff resistance. Heavy-duty DLC-coated tool steel wrist pins, clips and a high-performance ring set rounds out the PowerPak.

“Diesel motorsports is all the rage from NHRDA, ODSS to Ultimate Callout Challenge,” MAHLE Motorsport Program Manager, Joe Maylish said. “We’re excited to announce that MAHLE Motorsport is coming in strong for 2023 with new diesel piston sets in time for this year’s race season. So, if you are a seasoned competitor needing an edge or just thinking about competing this year, our new Powerstroke kits are designed to give you the edge on the weekends and improve performance throughout the week.”

For more information about MAHLE Motorsport’s full line of Ford Powerstroke cast PowerPak Piston sets, visit