6.0L Ford Power Stroke Engine - Every 6.0L Problem Solved

A possible explanation for why the '04 to '07 EGR coolers tend to fail more than the earlier versions is because a round tube flows better than a square one. At Diesel Tech we found a whole box of failed '04 to '07 coolers. According to Loren Taylor, retrofitting an '03-style EGR cooler onto newer engines is not out of the question for those wishing to keep their EGR systems intact and experience fewer problems.

Stuck or plugged EGR valves are a common problem on every model year 6.0L Power Stroke. The EGR valve on the left should give you an idea of just how much carbon and soot accumulates on these over time. It should also be noted that removing the EGR valve is a delicate process, and the recommended tool from Ford (PN 303-760) should be used when pulling it.

According to Diesel Tech, '06 models were most affected by failing O-rings on oil rail plugs. Over time the O-rings wear, and eventually oil pressure blows them out.

Gilbert Garcia of Diesel Tech told us he sees at least one truck each week with a blown oil rail plug. The most common symptom experienced when an oil rail plug fails is a long crank, no start situation.

Sticking vanes in variable geometry turbos (VGT) were very common on '03 to '06 models due to both an inferior turbo design, and a restrictive turbo oil drain tube. The '03 to '05 drain tube (top) was known for limiting oil flow to the point where it couldn't exit the turbo quick enough, resulting in backed up oil sitting and coking rather than lubricating the turbo vanes. The upgraded style drain tube (bottom) can be found on '06 and '07 engines and can be used to replace '03-to-'05-style units. Elite Diesel also informed us that '07-model turbos came with an internal groove that allowed soot and oil to pass through (no buildup as a result), which greatly reduced scenarios where vanes would stick open or closed. The '03-to-'06-style turbos do not have this internal groove.

Troubleshooting the complexities that come with a hydraulically actuated fuel injection (HEUI) system can stump most of us. While rear main seal leaks have been found on some 6.0L's, the guys at Diesel Tech told us that most owners who discover oil under their '03 Super Dutys often assume the worst, when in reality it's a failed injection control pressure sensor (ICP), which is located under the turbo at the rear of the engine valley.

One problem that is not particularly frequent but worth mentioning is that some intercooler tubes near the turbo inlet are prone to cracking. The only thing is, they're prone to cracking on the side you can't see.

This kind of a crack will cause a serious loss of power and will stump the average troubleshooter. The guys at Diesel Tech said the only way to find the crack is to slide a mirror underneath the tube.

Oil cooler failures are common on all 6.0L's. Oftentimes they become restricted (plugged up) on the coolant side, and other times the gasket fails. Both are easy fixes, but the problem is gaining access to the oil cooler itself that becomes the headache.