6.0L Power Stroke Fixes
Solutions to Common 6.0L Power Stroke Failures
Upgrading problematic components on the 6.0L Power Stroke nearly guarantees the longevity and reliability of the engine. These upgrades are by no means required for stock 6.0 liters, but grant owners peace of mind and worry free operation for hundreds of thousands of miles. When power output is increased by means of aftermarket components, these upgrades are recommended to prevent component failures. With a little work, the 6.0L Power Stroke can be upgraded to be as bulletproof as any other diesel on the market. (Note: We're not saying the 6.0L is not strong. However, many of the emissions related components have design flaws that can haunt 6.0L owners.)
Upgraded EGR Cooler:
Many companies now manufacture aftermarket EGR coolers that flow significantly better than the stock unit. This enhances the heat transfer characteristics of the EGR cooler, and ensures that the unit will not clog, which can set off a chain reaction of problems. This is especially recommended when performance is increased, as increased soot production can clog the stock EGR cooler in a hurry. 2004+ coolers are more susceptible to failure than 2003 model coolers.
Aftermarket Head Studs:
If the EGR system is clean and working properly, head studs are not required for engines at stock performance levels. Nonetheless, head studs increase the clamping force of the cylinder heads and prevent head gasket failures. The stock TTY (torque to yield) head bolts stretch quite a bit under load; a set of head studs alone bulletproofs the 6.0L Power Stroke. If your truck is putting out more horsepower/torque than stock via aftermarket components, head studs are essential. Increased cylinder pressures will stretch the TTY head bolts in a hurry, resulting in head gasket failure.
Upgraded Oil Cooler:
Oil coolers on the 6.0L have been known to become clogged and fail, often resulting in oil contamination of the cooling sytem. While keeping fresh engine oil and coolant in the engine can prevent this, a high flowing aftermarket oil cooler provides added protection.
EGR Block Off:
An EGR block off is not street legal, so if you live in a state that performs emissions testing, you're better off upgrading the EGR cooler and keeping the EGR valve clean. However, if your truck does not require inspection, an EGR block off is an option that will completely seal off the EGR system, eliminating problems that result from the systems poor design.
Bypass Oil Filter:
A bypass oil filter keeps the engine oil clean by removing tiny soot particles from the oil. This eliminates concerns of oil contamination that can reduce the life of the turbocharger, high pressure oil pump, and HEUI injectors. Any diesel will benefit form a bypass oil filter, not just the 6.0L Power Stroke. The HEUI injectors and HPOP (high pressure oil pump) are sensitive to dirty oil, but a bypass filter eliminates these concerns. If you plan on increasing the performance of your 6.0L, make sure to include head studs in your budget and address the factory EGR system.
Recommendations:
Install ARP head studs and a quality bypass oil filter. While the heads are off, replace the factory head gasket with a quality unit. This will nearly eliminate the chances of a head gasket failure. The bypass oil filter will protect the engine from oil contamination, especially the HEUI injection system components (which are expensive and difficult to replace). If a new EGR cooler is puts you over your budget, routinely clean the EGR valve and do not replace the cooler unless it fails or you notice the engine coolant temp running a little high. Replace your coolant at the recommended intervals to prevent oil cooler failures caused by particulates in the coolant. If your truck is exempt from inspection, block off the EGR and your will never have to worry about the associated problems. If money is not an option, perform all of the above and enjoy your new, improved, bulletproof 6.0L Power Stroke.
Additional Notes:
- ARP is the industry's leading manufacturer of aftermarket head studs for the 6.0L Power Stroke.
- Head stud installation usually requires removal of the cab. Ford knows this, and as a result designed the Super Duty so that removing the cab is easier than it sounds. Cab-off repairs are common for diesel powered Super Duty trucks. While it is possible to install them with the cab on, removal of the cab actually reduces installation time.
- Stock 6.0L Power Strokes do not require the aftermarket components discussed above to be reliable. The remedies described simply prevent the possibility of many common failures.
- The author of this article is the owner of a stock 2003 6.0L Power Stroke with 150,000 miles of trouble free operation. He plans on installing many of the upgrades discussed above in the near future to promote longevity of the engine.