2003-2007 6.0L Powerstroke

The 7.3L Power Stroke was replaced by the 6.0L beginning in the second quarter of the 2003 model year. The 6.0L Power Stroke was used in Ford Super Duty trucks until the 2008 model year but lasted until 2009 in Ford Econoline vans (Model Year 2010). It utilizes a variable geometry turbocharger and intercooler, producing 325 hp (242kW) and 570 lb-ft (773 N-m) torque.

If you own or are thinking of purchasing a 2003 to 2007 Ford Power Stroke you should be made aware of the many problems associated with the 6.0L engine. These problems are not a matter of if they will happen but a matter of when they happen. To properly diagnose the 6.0L it can take several hours with an experienced Diesel technician.

Once the issues have been fixed the 6.0L is a good and very reliable powerful engine. The bad news is that it will cost thousands of dollars to make this happen. It is more cost effective to fix the issues all at once before they happen rather than fixing them as they happen one at a time. The money saved could be $2000 up to $4000 due to the labor cost involved for each individual repair.

Updated Oil Cooler

The original OEM oil cooler was engineered with narrow interior passageways that are prone to clogging. Debris in the coolant, such as casting sand left over from the manufacturing process, would collect over time and cause a coolant restriction within the oil cooler. A plugged up engine oil cooler can lead to a ruptured EGR cooler, overheated engine oil, overheated fuel injectors, loss of coolant, ruptured engine oil cooler and blown head gaskets. Newest version of oil cooler for the 6.0L Powerstroke has thicker internal fins to minimize chance of cooler failure.

Key Benefits:

  • More effective engine oil cooling
  • Prevent EGR cooler failure due to poor coolant flow
  • Reduced engine oil temperatures

EGR Valve/Cooler Delete Kit

The 6.0L Powerstroke EGR cooler is notorious for cracking, causing coolant loss and overheated engines. This issue has prompted many performance parts manufacturers to develop EGR delete kits which eliminate the EGR cooler, as well as eliminating operation of the EGR system.

Key Benefits:

  • Eliminate possibility of engine overheating caused by failed EGR cooler
  • Quicker turbo spool with lower EGT’s
  • Faster recirculation of the coolant resulting in lower coolant temps
  • Unrestricted up-pipe for better exhaust flow

Fuel Pressure Regulator “Blue Spring” Upgrade Kit

1 of 3 injector failures is due to fuel starvation. Pressurized fuel in the injector is used to provide a cushioning action for the internal valving of the injector, low fuel pressure will severely harm the injectors.

In addition to proper fuel filter maintenance, installing the new updated Ford “Blue Spring” is recommended. The updating fuel pressure regulator will increase your fuel pressure back up to where it should be from the factory. Most 6.0′s see an increase of 10 psi of fuel pressure.

Key Benefits:

  • Prevent injectors damage from low fuel pressure
  • Quicker spool up on the turbo
  • Quieter idle

STC HPOP Fitting Update Kit

The “snap-to-connect” or STC fitting used to connect the high pressure oil pump to the oil supply branch tube has been problematic. The two piece fittings have a tendency to flex causing wear on the seal and the locking ring resulting in leaks and occasionally the complete separation of the fitting. When a leak occurs at this fitting, the engine may be difficult to start or may not start at all. Depending on the severity of the leak the engine may stall, sometimes abruptly and without warning.

The Ford 6.0 STC HPOP Fitting Update Kit is a New One-Piece High Pressure Oil Connector.

Key Benefit:

  • Eliminate STC fitting failures

Coolant Filtration System

Many diesel engines – like the Powerstroke – are cast with sand in the process. This sand is NOT completely removed from the system. In fact, much of this sand leaches out of the casting over time. The sand wears away at water pump seals, hoses and radiators. Installing a coolant filtration system will remove the debris from the cooling system.

Key Benefits:

  • Protect engine oil cooler
  • Protect EGR cooler
  • Greatly increase your water pump life

ARP Head Studs

ARP fasteners make the best and strongest engine head studs on the market today. Your 6.0 came from the factory with head bolts. The factory head bolts were designed to stretch but over time the bolts stretch past the designed length and allow the gaskets to leak.

Key Benefit:

  • with ARP head studs there is no more stretch thus preventing issues with blown head gaskets.

Cold Start FICM

The FICM (fuel injection control module) is a computer that runs the fuel injectors, it supplies 48 volts to the injectors and when this starts to fail the 6.0L will have a hard start or no start issue, rough idle and loss of power. When these modules fail, we recommend upgrading to the 58-volt Ford Injection Control Module (FICM). All applicable critical components voltage and temperature ranges have been increased which maximizes current output without setting an overvoltage code. These exchange units come preprogrammed and ready to install.

Key Benefits:

  • Quicker, more affirmative starts in both cold and warm weather over the OEM versions
  • Better throttle response
  • Slight increases in horsepower