6.0 Powerstroke Upgrades: Fix the Weak Points, Then Add Power

The 6.0 Powerstroke has a reputation, and most of it comes from a handful of known weak points. Fix those and a 6.0 is a strong, fast truck that tows well. Skip them and add power, and you are usually buying head gaskets. Here is the order we follow in our shop: make it reliable first, then add power in steps.

Step 1: Know Which 6.0 You Have

Ford used the 6.0 in 2003 to 2007 F250 and F350 Super Duty trucks, the Excursion and E series vans. A lot of parts changed during the run. The high pressure oil system, the turbo and the head dowels are different between early and late engines, so order by year and build date. When in doubt, send us your VIN.

Step 2: Fix the Weak Points

Head studs

The 6.0 has only four head bolts around each cylinder, and the factory bolts are torque to yield. Under high cylinder pressure from a tune, heavy towing or an overheating EGR cooler, they stretch and the head gaskets let go. Studs are the fix.

• ARP 6.0 Powerstroke head stud kit
• ARP CA625+ head stud kit for high boost and high horsepower builds
• XDP X220 Series head stud kit (XD3001HS)

Earlier engines use 18mm head dowels and later 2006 and 2007 engines use 20mm, so gaskets and heads are not interchangeable: Mahle 18mm gasket set, Ford 20mm head gasket. If the heads are already off, read our 6.0 and 6.4 cylinder heads guide.

Oil cooler and EGR cooler

These two fail together. The coolant side of the factory oil cooler plugs up with casting sand and broken down coolant. Less coolant gets through to the EGR cooler, it overheats and eventually ruptures, and coolant ends up in the intake.

• Check the oil cooler: with the truck fully warm, compare engine oil temperature to coolant temperature on a scan tool or monitor. The common rule of thumb is that a gap of more than 15 degrees F means the oil cooler is restricted.
• Signs of a failed EGR cooler: losing coolant with no visible leak, white smoke with a sweet smell, or coolant pushing out of the degas bottle.
• Oil cooler: Mishimoto replacement oil cooler kit, aFe BladeRunner oil cooler, Ford oil cooler
• EGR cooler: aFe BladeRunner for 2003 to 2004 and 2004 to 2007 (square), aFe square replacement with gaskets, BD round cooler for 2003 to early 2004
• Keep it clean: a coolant filter kit catches the sand before it plugs the new cooler. BD Diesel coolant filter kit, Mishimoto in black or blue hoses.

FICM and batteries

The FICM supplies 48 volts to fire the injectors. When it weakens you get long cranking, hard cold starts, rough running and misfires. Weak batteries and charging problems are hard on it, so test those first.

The easiest way to catch a failing FICM is FICM voltage. Check it with a scan tool. If it drops below 47 volts, the FICM is on its way out.

• Alliant FICM (AP6512X), comes pre programmed and ready to install
• BD Diesel 58 volt FICM
• Ford FICM harness (5C3Z-9D930-A)

High pressure oil leaks

The injectors are fired by high pressure oil. A leak anywhere in that system means a hard start or no start, usually worse when the engine is hot.

• Ford STC fitting update kit for the high pressure oil pump on 2004.5 to 2007 engines
• Ford updated standpipe and dummy plug kit
• Ford ICP sensor and Ford IPR valve

Fuel pressure

Low fuel pressure is hard on 6.0 injectors. The cheapest fix is the Ford blue spring kit, which raises fuel pressure over the factory spring. For more, add a regulated return: J&J Performance, Industrial Injection or Smeding Diesel. Add a lift pump like the AirDog II-5G DF-165 or FASS Titanium 220 GPH, and the J&J fuel bowl delete once the lift pump handles the filtering. Our lift pump guide covers sizing.

Step 3: Tuning

Once the weak points are handled, a tune is the best value on a 6.0. Our 6.0 custom tuning is the most popular 6.0 item we sell, and we also offer FICM tuning for trucks with bigger injectors or a custom oil pressure setup.

Devices to load tunes: SCT X4 7015 package, SCT Livewire TS+ 5015P, SCT BDX 40490, Edge CTS3 Evolution and the KC CTS3 Evolution. Add an Edge Insight CTS3 monitor so you can watch oil and coolant temps every day. Read our 6.0 tuner guide before you buy, and check your state's emissions rules.

Step 4: Injectors and High Pressure Oil

Bigger injectors make the power on a 6.0, but they need more high pressure oil to fire them, a turbo that can keep up and a tune written for them. Replace injectors as a set.

• Injectors: stock, 155cc, 175cc, 190cc, 205cc and 225cc sets, plus 7mm and 8mm hybrids
• High pressure oil pump, 2003 to 2004: CNC Fabrication Stage 1 (supports 190cc or smaller per CNC), Atlas billet Stage 2
• High pressure oil pump, 2005 and newer: RCD Thumper I (RCD lists support up to 225cc conventional injectors) and Thumper II
• Oil supply: RCD billet low pressure oil pump gear set, Warren Diesel billet LPOP gear, Warren Diesel 7250 PSI ICP sensor and high pressure IPR valve

Not sure your injectors are the problem? Read signs your diesel injectors are failing.

Step 5: Turbo and Air

The factory turbo is a variable geometry unit, and soot can stick the vanes. Pick the turbo for the injectors you run:

• Garrett stock replacement turbo for 2004 to 2005
• KC Stock Plus billet turbo: drop in, KC lists it for stock to 155cc injectors
• KC Jetfire Stage 1: KC lists it for injectors up to 175cc
• KC Jetfire Stage 2 for bigger builds
• Smeding non VGT S300 kit for trucks that want a fixed geometry turbo

On the air side, the No Limit 6.0 cold air intake and No Limit air to air intercooler. See all 6.0 turbos and exhaust and 6.0 intakes and cooling.

Step 6: Put the Power Down

More torque means more axle wrap. Traction bars for 1999 to 2010 Super Duty and the Pro Form Fab fixed length 4 link for 2005 to 2016 are the two most popular fixes we sell for these trucks. Our Pro Form Fab suspension guide explains the difference. The automatic behind a built 6.0 needs help too: see 6.0 transmissions.

Step 7: When the Engine Itself Is Tired

If the bottom end is worn or the heads are cracked, fix the engine before you add power. We build a 6.0 short block and sell new casting 6.0 cylinder heads machined in house. Read our short block buyer guide for what to look for.

Recommended Order by Build

Shop 6.0 Powerstroke Parts

• 6.0 engine parts • 6.0 fuel system • 6.0 injectors • 6.0 tuning
• 6.0 turbos and exhaust • 6.0 intakes and cooling • all 6.0 Powerstroke parts

FAQ

What should I upgrade first on a 6.0 Powerstroke?

Fix the weak points before adding power: head studs, a healthy oil cooler and EGR cooler, a strong FICM and batteries, the high pressure oil fittings and steady fuel pressure. Then add a tune.

How do I know if my 6.0 Powerstroke oil cooler is clogged?

Compare engine oil temperature to coolant temperature with a scan tool or monitor once the truck is fully warm. The common rule of thumb is that a gap of more than 15 degrees F points to a restricted oil cooler.

Do I need head studs before tuning a 6.0 Powerstroke?

We recommend it. The factory torque to yield head bolts can stretch under higher cylinder pressure, and a blown head gasket costs far more than a set of studs.

What does a bad FICM do on a 6.0 Powerstroke?

The FICM supplies 48 volts to fire the injectors. When it gets weak you will see hard or long cranking starts, rough running and misfires, often worse when it is cold. The easiest way to catch it is FICM voltage on a scan tool: if it drops below 47 volts, the FICM is failing. Low battery voltage makes it worse.

What turbo should I run with bigger injectors on a 6.0?

Match the turbo to the injector. KC lists its Stock Plus turbo for stock to 155cc injectors and its Jetfire Stage 1 for injectors up to 175cc. Bigger injectors also need more oil from the high pressure oil pump and a tune built for them.

Are 6.0 Powerstroke head gaskets 18mm or 20mm?

Both were used. Earlier engines use 18mm head dowels and later 2006 and 2007 engines use 20mm, so heads and gaskets are not interchangeable. Check your engine or send us your VIN before you order.

Not sure what fits your truck? Send us your VIN or call 865 640 2097 and we will help you pick the right parts.

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