Comprehensive Ford 6.0L Powerstroke Maintenance Guide

Are you an owner of a 2003-2007 Ford Superduty with the 6.0L Powerstroke engine? If you did any research before buying your truck, you’re probably aware of the wide array of 6.0L Powerstroke problems that can occur throughout the ownership of your truck. While these trucks have a bad reputation, one of the biggest factors affecting the 6.0L Powerstroke engine’s reliability and longevity is if you maintain your truck properly. Proper 6.0L Powerstroke V8 Diesel engine Maintenance can go a long way in dramatically increasing the life of your truck and limiting the amount of problems you encounter.

In this post, our comprehensive Ford F-250/F-350 Superduty 6.0L Powerstroke Maintenance guide, we’re going to give you a detailed blueprint on how to make your truck more reliable. We’ll provide you with manufacturer recommended 6.0L Powerstroke maintenance intervals and provide charts displaying fluid and engine oil capacity. Furthermore, we’ll list the best 6.0L Powerstroke engine engine oil, fluids, and maintenance parts that you’ll need along the way. Finally, We cap it off by answering common 6.0L Powerstroke maintenance questions and recommending some of our favorite aftermarket 6.0L Powerstroke upgrades that can make your 6.0L Powerstroke more reliable.

6.0L Powerstroke Ford Superduty

Ford Superduty 6.0L Powerstroke Maintenance Intervals

The first step in understanding how to maintain your Ford F-250 or F-350 with the 6.0L Powerstroke engine is knowing how frequently your truck needs service. Ford has two separate recommended sets of maintenance intervals. They are based upon how the truck in question is used.

For the average driver, who uses the truck as a primary vehicle and tows infrequently, the normal operating conditions maintenance intervals are intended to be followed. For commercial/fleet vehicles, or trucks that tow frequently, the severe operating conditions maintenance intervals are recommended.

Since these trucks being on the road for decades now, we’ve actually come up with our own set of maintenance intervals. These trucks are incredibly hard on engine oil and coolant. Even trucks that are pampered should still be maintained more frequently. We’ll include our recommended 6.0L Powerstroke Service intervals as well.

Normal Operating Conditions

These are the recommended Ford maintenance intervals for vehicles falling under the normal operating conditions category. These trucks include daily drivers, commuters, and light towing.

Maintenance/Service TypeMilesKilometers
Change Oil7,500 miles12,000 km
Change Oil
Filter
7,500 miles12,000 km
Change Fuel
Filter(s)
15,000 miles24,000 km
Replace Air
Filter
Check Filter restriction
gauge. Replace
as necessary.
Check Filter restriction
gauge. Replace
as necessary.
Flush Cooling
System
100,000 miles160,000 km
Replace Auto
Transmission
Fluid
30,000 miles48,000 km
Replace Manual
Transmission
Fluid
60,000 miles96,000 km
Change External
transmission filter
30,000 miles48,000 km
Change internal
transmission filter
30,000 miles48,000 km
Replace Transfer
Case Fluid
150,000 miles240,000 km
Install new accessory
drive belt(s)
150,000 miles240,000 km
Replace Rear
Differential Fluid
150,000 miles240,000 km
Replace Front
Differential Fluid
150,000 miles240,000 km

Severe Operating Conditions

For vehicles that are used for commercial/fleet applications, those who tow frequently, or those idling frequently should follow the Severe Operation Conditions maintenance schedule listed below.

Maintenance/Service TypeMilesKilometers
Change Oil5,000 miles8,000 km
Change Oil
Filter
5,000 miles8,000 km
Replace Fuel
Filter(s)
10,000 miles16,000 km
Replace Air
Filter
Check Filter restriction
gauge. Replace
as necessary.
Check Filter restriction
gauge. Replace
as necessary.
Flush Cooling
System
Every 40-50,000 miles
or once every 1-2 years.
64-80,000 km or
once every 1-2 years.
Replace Auto
Transmission
Fluid
30,000 miles48,000 km
Replace Manual
Transmission
Fluid
60,000 miles96,000 km
Change External
transmission filter
30,000 miles48,000 km
Change internal
transmission filter
30,000 miles48,000 km
Replace Transfer
Case Fluid
60,000 miles96,000 km
Replace Rear
Differential Fluid
50,000 miles80,000 km
Replace Front
Differential Fluid
50,000 miles 80,000 km

What is the best 6.0L Powerstroke V8 Maintenance Schedule to Follow?

The best 6.0L Powerstroke V8 Diesel maintenance schedule is a combination of the normal operating conditions and severe operating conditions maintenance schedules. Because these trucks are so hard on engine oil and coolant, these trucks need to be maintained more frequently. Oil and coolant quality is incredibly vital in making sure you don’t have any problems. Here is our recommended maintenance schedule to follow.

Best Ford Superduty 6.0L Powerstroke Maintenance & Service Schedule

Maintenance/Service TypeMilesKilometers
Change Oil5,000 miles8,000 km
Change Oil
Filter
5,000 miles8,000 km
Replace Fuel
Filter(s)
10,000 miles16,000 km
Replace Air
Filter
Every 20-30,000 miles. Check
every oil change and change
as needed.
Every 32,000-48,000 km.
Check every oil change and
change as needed.
Flush Cooling
System
Every 40-50,000 miles
or once every 1-2 years.
64-80,000 km or
once every 1-2 years.
Replace Auto
Transmission
Fluid
30,000 miles48,000 km
Replace Manual
Transmission
Fluid
60,000 miles96,000 km
Change External
transmission filter
30,000 miles48,000 km
Change internal
transmission filter
30,000 miles48,000 km
Replace Transfer
Case Fluid
100,000 miles/60,000 miles under
severe operating conditions
240,000 km/96,000 km under
severe operating conditions.
Replace Rear
Differential Fluid
100,000 miles/30,000 miles under
severe operating conditions
160,000 km/ 48,000 km under
severe operating conditions
Replace Front
Differential Fluid
100,000 miles/30,000 miles under
severe operating conditions
160,000 km/ 48,000 km under
severe operating conditions

Ford Superduty 6.0L Powerstroke Fluid Capacity

Before you go and purchase 6.0L Powerstroke engine oil, coolant, or other forms of fluids that are listed below, you need to know how much of each specific fluid your vehicle needs. The following chart displays how much of each fluid type your vehicle needs. Be aware, you should always check the appropriate dipstick or fluid level indicator to make sure you are putting in the correct amount of fluid.

Oil/FluidCapacity – QuartsCapacity – Liters
Engine Oil15 Quarts /w filter14.2 Liters
Auto Transmission Fluid17.5 Quarts16.6 Liters
Manual Transmission Fluid5.8 Quarts5.5 Liters
Transfer Case2 Quarts1.9 Liters
Engine Coolant27.5 Quarts26 Liters
Front Differential Fluid
(Dana 60)
3 Quarts2.8 Liters
Rear Differential Fluid
Sterling 10.50″
Dana 80
Dana S110
Dana S130
See Below
3 Quarts
3.5 Quarts
6.98 Quarts
6.98 Quarts
See Below
3.3 Liters
4.0 Liters
6.6 Liters
6.6 Liters

6.0L Powerstroke Engine Oil, Filters, and Fluids

The best oil and filters to use for any diesel engine are ones that meet OEM standards. For Ford trucks, we strongly recommend sticking with Motorcraft oil, fluids, and filters. Listed below we will give you the best 6.0L Powerstroke Engine oil, coolant, and other fluids. We’ll also list the best 6.0L Powerstroke filters to use, and even a list of maintenance parts too.

Ford Superduty 6.0L Powerstroke Engine Oil

Engine oil typeOutdoor Ambient TemperaturePart #
Buy it on Amazon
Part #
Buy it at Walmart
SAE
15W-40
Acceptable at temperatures
over 10 degrees Fahrenheit.
Recommended Oil for temperatures
over 30 degrees Fahrenheit.
Motorcraft XO-15W40-5Q3SDMotorcraft XO-15W40-5Q3SD
SAE
10W-30
Preferred engine oil at temperatures between
30 to -10 degrees Fahrenheit.
Acceptable at temperatures
from -10 to 90 degrees
fahrenheit.
Motorcraft XO-10W30-5Q3SDMotorcraft XO-10W30-5Q3SD
SAE
5W-40
Acceptable at temperatures
30 degrees or less.
Motorcraft XO-5W40-5QSDMotorcraft XO-5W40-5QSD

Ford Superduty 6.0L Powerstroke Fluids

Fluid TypePart #
Buy it on Amazon
Coolant
Concentrated:
Pre-diluted:
Concentrated: Motorcraft VC-7-B
Pre-diluted: Motorcraft VC-7-DILB
Automatic
Transmission Fluid
Motorcraft Mercon SP ATF
Manual Transmission
Fluid
Motorcraft Mercon V
Transfer Case
Fluid
Motorcraft Mercon V
Front Differential
Fluid
Motorcraft SAE 80W-90 Premium Rear Axle Lubricant
XY-80W-90–QL
Rear Differential Fluid
Sterling 10.50″
Dana 80
Dana S110
Dana S130
See Below *(May need to add Additive)*
Motorcraft SAE 75W-140 XY-75W140–QL 
Motorcraft SAE 75W-90 XY-75W90–QLS
Motorcraft SAE 75W-140 XY-75W140–QL
Motorcraft SAE 75W-140 XY-75W140–QL

Ford Superduty 6.0L Powerstroke Filters

Part TypePart #
Engine Oil FilterFord: 3C3Z-6731-AA
Motorcraft FL-2016
Oil Filter CapFord: 3C3Z-6766-CA
Motorcraft EC-781
Fuel FilterFord: 3C3Z-9N184-CB
Motorcraft FD-4616
Engine Air FilterFord: 4C3Z-9601-AA
Motorcraft FA-1778
External Transmission 
Filter
Motorcraft FT-145 
(Re-Use your O-Ring)
Internal Transmission 
Filter
Motorcraft FT-144

6.0L Powerstroke Common Replacement and Service Parts

When looking at the parts your Ford Superduty with the 6.0L Powerstroke needs, it’s important to recognize which model you have. Trucks produced before 09/22/03 will fall into the 2003-2004 category. Trucks produced after this date will fall into the 2004.5-2007 category.

Comprehensive 2003-2007 6.0L Powerstroke Parts Lists

Have something wrong with your 6.0L Powerstroke engine? Check out these frequently needed replacement parts. We’ve included both OEM Ford/Motorcraft 6.0L Powerstroke replacement parts and also some aftermarket alternatives.

OEM Ford/Motorcraft 2003-2007 Ford Superduty 6.0L Powerstroke Replacement Parts

Often times, the OEM replacement parts are the best parts to use in your 6.0L Powerstroke. Here are many of the most commonly needed 6.0L Powerstroke OEM replacement parts.

OEM Parts List

Part TypeOEM Part #
EGR Valve
2003-2004
2004.5-2007
See Below
Ford 4C3Z-9F452-A /Motorcraft CX2722
Ford 5C3Z-9F452-AA/Motorcraft CX2733
EGR Cooler
2003-2004
2004.5-2007
See Below
Ford 3C3Z-9P456-B
Ford 4C3Z-9P456-AJ
Oil Cooler
2003-2007
Ford 3C3Z-6A810-A
Oil Cooler
Screen
2003-2007
Ford 3C3Z-6C683-AB
HPOP
2003-2004
2005-2007
See Below
Ford 4C3Z-9A543-AARM/Motorcraft HPP10RM
Ford 5C3Z-9A543-ARM/Motorcraft HPP12RM
Injectors
2003-2004
2004.5-2007
See Below
Ford 3C3Z9E527ARM/ Motorcraft CN5020
Ford 4C3Z9E527BRM / Motorcraft CN5019
Glow Plugs
2003-2004
2004.5-2007
See Below
Motorcraft ZD12
Motorcraft ZD13
Glow Plug Harness
Driver Side
2003-2004
2004.5-2007
See
Below
Ford 3C3Z-12A690-AA
Ford 5C3Z-12A690-A
Glow Plug Harness
Passenger Side
2003-2004
2004.5-2007
See
Below
Ford 3C3Z-12A690-BA
Ford 4C2Z-12A690-AB
IPR Valve
2003-2004
2004.5-2007
See Below
Ford 3C3Z-9C968-AA
Ford 5C3Z-9C968-CA
ICP Sensor
2003-2004
2004.5-2007
See Below
Ford 3C3Z-9F838-EA
Ford 4C3Z-9F838-A
ICP Sensor Pigtail
2003-2007
Ford 5C3Z-12224-A
Camshaft Position
Sensor
2003-2007
Ford 8C3Z-12K073-A
Motorcraft DU-88
Camshaft Position
Sensor Pigtail
2003-2007
Ford 3U2Z-14S411-JCA
Crankshaft
Position Sensor
2003-2007
Ford 3C3Z-6C315-AA
Motorcraft DY-985
Engine Oil
Pressure Sensor
2003-2007
Ford F81Z-9278-AA
Motorcraft SW-5267
Engine Oil
Temperature Sensor
2003-2007
Ford 3C3Z-10884-AA
Motorcraft SW-6052
Exhaust Back
Pressure Sensor
2003-2004
2005-2007
See
Below
Ford 4C3Z-9J460-A / Motorcraft DPFE-3
Ford 5C3Z-9J460-B / Motorcraft DPFE-6
Serpentine Belt
2003-2007
(Single ALT)
Motorcraft JK8-1267-A
Belt Tensioner
(Single Alt)
Ford 3C2Z6B209AA
Motorcraft BT-70
Thermostat
2003-2007
Ford 3C3Z-8575-AA
Motorcraft RT1169
Water Pump
2003-2004
2004.5-2007
See Below
Ford 3C3Z-8501-A/ PW-480
Ford 4C3Z-8501-AC/ PW-491
Degas Bottle
/ Coolant Overflow
2003-2007
Ford 6C3Z-8A080-B
Bottle Cap For
Degas Bottle
Ford 9C3Z-8101-B
Motorcraft RS527
Turbocharger
2003-2004
2004.5-2005
Late 2005-2007
See Below
Ford 3C3Z-6K682-CCRM
Ford 4C3Z-6K682-CCRM/4C3Z-6K682-CDRM
Ford 5C3Z-6K682-CARM/5C3Z-6K682-CCRM
Turbo Oil
Return Drain Tube
2003-2007
Ford 3C3Z-9T516-A
Head Gasket Kit
2003-2006
2006-2007
See Below
Ford 4C3Z-6051-EB
Ford KC3Z-6051-B

Aftermarket 2003-2007 Ford Superduty 6.0L Powerstroke Replacement Parts

The 6.0L Powerstroke engine suffers from some critical design flaws that are still apparent in many new OEM parts. Check out some of these Aftermarket alternatives. They can significantly improve reliability on your Ford Superduty.

Part TypeAftermarket Solutions
Part #
EGR Valve
2003-2004
2004.5-2007
See Below
Sinister Diesel EGRV-FORD-03
Sinister Diesel EGRV-FORD-05
EGR Cooler
2003-2004
2004.5-2007
See Below
Bulletproof NT-EGRC-0
Bulletproof NT-EGRC-1
Oil Cooler
2003-2007
Mishimoto MMOC-F2D-03
PPE 314030310
Oil Cooler
Screen
2003-2007
Use OEM Only
HPOP High Pressure Oil Pump
2003-2004
2005-2007
See Below
Diesel Site HPOPB60
Diesel Site HPOP
Injectors
2003
2004.5-2007
See Below
Alliant AP60900
Alliant AP60901
Glow Plugs
2003-2004
2004.5-2007
USE OEM ONLY
Glow Plug Harness
Driver Side
2003-2004
2004.5-2007
USE OEM ONLY
Glow Plug Harness
Passenger Side
2003-2004
2004.5-2007
USE OEM ONLY
IPR Valve
2003-2004
2004.5-2007
USE OEM ONLY
ICP Sensor
2003-2004
2004.5-2007
USE OEM ONLY
ICP Sensor Pigtail
2003-2007
USE OEM ONLY
Camshaft Position
Sensor
2003-2007
USE OEM ONLY
Camshaft Position
Sensor Pigtail
2003-2007
USE OEM ONLY
Crankshaft
Position Sensor
2003-2007
USE OEM ONLY
Serpentine Belt
2003-2007
(Single ALT)
USE OEM ONLY
Belt Tensioner
(Single Alt)
USE OEM ONLY
Thermostat
2003-2007
Mishimoto Low Temperature Thermostat MMTS-F2D-03FL
Mishimoto High Temperature Thermostat MMTS-F2D-03FH
Water Pump
2003-2004
2004.5-2007
See Below
Bulletproof 90201050
Bulletproof 90201049
Degas Bottle
/ Coolant Overflow
2003-2007
Mishimoto MMRT-F2D-03P (Polished)
Mishimoto MMRT-F2D-03BK (Black)
Sinister ‎SD-DEGAS-6.0
Bottle Cap For
Degas Bottle
USE OEM ONLY
Turbocharger
2003-2004
2004.5-2005
Late 2005-2007
See Below
Garrett Powermax Stage 1
Garrett Powermax Stage 1
Garrett Powermax Stage 1
Turbo Oil
Return Drain Tube
2003-2007
USE OEM ONLY
Head Gasket Kit
2003-2006
2006-2007
See Below
Mahle HS54450 (18mm)
Mahle HS54579 (20mm)
Head Stud Kit
2003-2007
ARP 250-4202 Head Stud Kit
ARP 250-4205 Age 625+ Head Stud Kit

Best 6.0L Powerstroke Aftermarket Upgrades To Improve Reliability

There are a number of aftermarket upgrades that not only improve performance, but can also help make your 6.0L Powerstroke more reliable. They can help you identify problems early, or solve some common 6.0L Powerstroke problems altogether. Check out some of our favorite 6.0L Powerstroke Aftermarket solutions to make your truck more reliable.

Real-time Performance Monitors

Every truck, especially the 2003-2007 Ford Superduty with the 6.0L Powerstroke V8 Diesel engine, can benefit from a performance monitor. Often also referred to as digital gauge displays, these devices offer real-time data on truck performance, trouble-code reading/clearing, and can even be used in conjunction with accessory EGT sensors. They can help identify problems early and are incredibly valuable. I put one on every truck I own.

Edge Insight CTS3

Edge Insight CTS3

The Edge Insight CTS3 monitor is one of the most intuitive and capable 6.0L Powerstroke Performance Monitors. It gives you real-time parameters that make monitoring your truck easy! They’re easily upgraded with numerous accessories like EGT sensors too. Find out more information in our Edge Insight CTS3 Review.

Edge Evolution CTS3

If you want tunes for your truck in addition a performance monitor, the Edge Evolution CTS3 offers you everything the CTS3 has with additional 6.0L Powerstroke tunes. Check out our 6.0L Powerstroke Tuning guide for more information. Just be careful, as tuning is an upgrade that can actually decrease reliability when it is done without additional supporting modification.

Edge Evolution CTS3 6.0L Powerstroke

Ford Superduty 6.0L Powerstroke Coolant Filtration Kits

Engine coolant plays a critical role in the EGR and Oil cooling processes that are used within the 6.0L Powerstroke V8 Diesel engine. While proper maintenance helps maintaining coolant quality, a coolant filtration kit is a cheap aftermarket upgrade that can go a long way towards preventing catastrophic failures. Check out some of our favorite coolant filtration kits that help prevent common 6.0L Powerstroke problems.

Mishimoto Coolant Filtration System

Mishimoto Coolant Filtration Kit

The 6.0L Powerstroke engine is extremely hard on engine coolant. Once coolant breakdown occurs, it can cause all kinds of different 6.0L problem problems, and it will cause the need for more frequent coolant changes. Mishimoto’s Coolant Filtration Kit is an easy to install upgrade that helps improve coolant quality and extends coolant change intervals.

Sinister Diesel Coolant Filtration Kit

The Sinister Diesel 6.0L Powerstroke Coolant Filtration Kit is another quality coolant filtration kit that helps improve coolant quality and your truck’s longevity.

Sinister Diesel 6.0L Powerstroke Coolant Filtration Kit

6.0L Powerstroke Intercooler Upgrades

The OEM 6.0L Powerstroke intercooler is restrictive, small, and features plastic end caps. Aftermarket 6.0L Powerstroke intercoolers are one of the best 6.0L Powerstroke upgrades because they lower EGTs and simultaneously improve power, fuel economy, and drivability. Check out some of our favorite 6.0L Powerstroke intercooler upgrades.

Banks TechniCooler Upgrade 2003-2004 6.0L Powerstroke

Banks Techni-Cooler Intercooler Upgrade Kit (2003-2004) 25974

The Banks Techni-Cooler Intercooler Upgrade kit for 2003-2004 Ford Superduty 6.0L Powerstroke trucks is a huge improvement over stock. It features aluminum end tanks and a thicker core. It’s also paired with less restrictive boost tubes. This mod provides the engine with cooler, denser air that ultimates translates into lower EGTs, improved MPG, more power, and better throttle response.

Banks Techni-Cooler Intercooler Upgrade Kit (2005-2007) 25975

Just like the kit above, the Banks Techni-Cooler Intercooler Upgrade kit for 2005-2007 Ford Superduty trucks with the 6.0L Powerstroke results in improved fuel economy, lower EGTs, and improved performance.

Check out our Best 6.0L Powerstroke Upgrades post for even more of the best 6.0L Powerstroke upgrades to improve performance, reliability, and fuel economy.

2003-2007 Ford Superduty 6.0L Powerstroke Maintenance FAQs

How much oil does the 6.0L Powerstroke engine take?

The 6.0L Powerstroke V8 Diesel engine requires 15 quarts of oil with the filter. This equates to 14.2 Liters.

What type of oil does the 6.0L Powerstroke v8 Diesel engine need?

According to Ford, the recommended 6.0L Powerstroke engine oil in temperatures above 10 degrees Fahrenheit is SAE 15w-40. In colder climates, other engine oils may be better suited for this engine. Ford recommends the use of Motorcraft XO-15W40-5Q3SD.

What engine oil filter does the 6.0L Powerstroke V8 Diesel engine need?

The best oil filter to use in the 6.0L Powerstroke engine is Motorcraft FL-2016.

How much engine coolant does a 6.0L Powerstroke need?

6.0L Powerstroke engines have a coolant capacity of 27.5 Quarts (26 liters).

What Engine Coolant does the 6.0L Powerstroke need?

Ford recommends the use of Motorcraft Motorcraft VC-7-B (Concentrate) or
Motorcraft VC-7-DILB (Pre-Diluted).

What is the correct Fuel Filter to use on the 6.0L Powerstroke engine.

Ford Superduty trucks with the 6.0L Powerstroke V8 Diesel engine need Motorcraft FD-4616.

Check Our Other Ford Superduty 6.0L Powerstroke Posts

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2003-2007 Ford F-250/F-350 Superduty 6.0L Powerstroke Guide

2003-2007 Ford F-250 and F-350 Superduty trucks contain one of the most well-known diesel engines in modern day diesel trucks, the 6.0L Powerstroke V8 engine. Upon being released, consumers had high hopes for this latest iteration of the Superduty. This was especially true considering this engine was replacing the legendary 7.3L Powerstroke V8 Diesel engine which had set the bar extremely high for Ford trucks.

Despite the reliability of its predecessor, the 6.0L Powerstroke became well-known for entirely different reasons. In this post, our 2003-2007 Ford F-250/F-350 Superduty 6.0L Powerstroke Guide, we’re going to dive in deep about the good, the bad, and the ugly of these trucks.

We’ll cover Ford Superduty 6.0L Powerstroke performance, specs, history, and tow ratings. We’ll also list common Ford Superduty 6.0L Powerstroke problems, and what can be done to fix them. Let’s get started.

Ford F-250 Superduty with the 6.0L Powerstroke V8 Diesel Engine

6.0L Powerstroke V-8 Diesel Engine

The 6.0L Powerstroke engine was built by International Navistar, similar to the 7.3L Powerstroke. Planning and design for this new engine began in the late 90s as Ford was aware of upcoming and stringent emissions guidelines that were being implemented. In addition to stricter emissions, the 7.3L Powerstroke was becoming underwhelming from a performance aspect. Both the 5.9L Cummins and the LB7 Duramax engines were catching up, or even surpassing the 7.3L Powerstroke in capabilities.

In 2003, Ford introduced the 6.0L Powerstroke engine in Ford F-250 and F-350 Superduty trucks. It was in production until the 2007 model year, after which it was replaced by the 6.4L Powerstroke V8 Diesel Engine.

Graphic Taken From a Ford Superduty Brochure
6.0L Powerstroke V8 Diesel engine Graphic taken from a Ford Superduty Brochure.

Engine Design

The 6.0L Powerstroke is a direct-injection, 32-Valve, 8-cylinder Diesel engine that boasts significantly improved power, fuel economy, and NVH (noise, vibration, harshness) over the previous 7.3L Powerstroke V8 Diesel engine. It also contains a lower displacement, and is more compact than the engine it replaced. This engine has an Overhead valve design, with a single, block-mounted camshaft, featuring hydraulic valve-lash adjustment. This results in lesser friction resulting in greater valvetrain durability, improved longevity, quieter operation, and better performance.

Utilizing a cast-iron cylinder block for superior strength, the 6.0L Powerstroke features a sturdy foundation. To help accomplish its compact design, the geartrain for the crankshaft, camshaft and the HPOP (high-pressure oil pump) were moved to the engine’s rear. Further bottom-end strength was accomplished by the use of a crankcase bed plate.

Similar to the 7.3L Powerstroke, powdered-metal connecting rods are used, with great success. These connecting rods have been found to be capable of supporting massive performance improvements. Cast Aluminum Pistons are also used.

6.0L Powerstroke engines contains cast iron cylinder heads, which are significantly higher flow than the outgoing 7.3L Powerstroke. Four valves are used per cylinder, for a total of 32 valves. Aluminum rocker boxes mount to the top of each cylinder head. The cylinder heads themselves are mounted to the block with four 14mm TTY head bolts used per cylinder. These Torque-to-yield bolts are small compared to those used in other diesel applications, and also fewer in number. They’re known to stretch when the engine is put under higher loads due to heavy towing or engine mods like 6.0L Powerstroke Tuning. Once they’ve stretched, they will no longer apply the same clamping force, ultimately resulting in a blown head gasket.

6.0L Powerstroke V8 Diesel engine
Ford 6.0L Powerstroke V8 Diesel engine. Picture Taken From PowerstrokeDiesel.com

Engine Highlights

The 6.0L Powerstroke V8 Diesel Engine brought some innovations never before seen on a Ford Diesel truck. These engines use EGR, or exhaust gas recirculation, as a means of significantly reducing emissions output and meeting federally mandated emissions requirements. Electronic Variable Response Turbocharging is introduced through the use of a variable geometry turbocharger. An updated fuel design also was introduced, helping to reduce emissions output and increase performance capabilities.

Exhaust Gas Recirculation (EGR)

Exhaust gas recirculation is the process in which cooled exhaust gases get re-circulated back into the combustion chamber. This lowers the burner temperature at which combustion occurs, ultimately leading to reduces NOx emissions.

While the EGR did help reduce emissions enough for Ford to meet emissions requirements, they essentially opened a can of worms. EGR failure is one of the most common 6.0l Powerstroke Problems. Exhaust gas recirculation is extremely hard on engine coolant and introduces excess carbon and soot into multiple components including the EGR valve, EGR Cooler, intake manifold, and more.

Picture above is the Sinister Diesel 2004-2007 Ford Superduty 6.0L Powerstroke EGR Cooler.

Variable Geometry Turbocharger & Electronic Variable Response Turbocharging

A revolutionary turbocharging system was introduced the 2003 Ford Superduty with the introduction of the 6.0L Powerstroke engine. A variable Geometry, Garrett GT3782VA turbocharger is used in conjunction with an air-to-air intercooler. This turbocharger optimizes boost and performance over a wide range of driving scenarios.

This variable geometry turbocharger, also called Electronic Variable Response Turbocharging, or EVRT, uses a set of electronically controlled, hydraulically actuated vanes. These vanes automatically adjust, changing airflow within the turbo. This design results in optimum performance in the entire operating range. At lower speeds, it functions as a smaller turbocharger, resulting in quicker spooling and faster response. At higher operating ranges, it functions as a larger turbo for maximum power output.

While extremely innovative, the VGT actually is a common 6.0L Powerstroke problem as well. The VGT can experience buildup that causes the vanes to get stuck. A thorough cleaning or total replacement can fix the problem. There are plenty of 6.0L Powerstroke aftermarket turbocharger upgrades available on the aftermarket.

2005.5-2007 Garrett GT3782 VA Stock Replacement Turbocharger

The stock 6.0L Powerstroke was incredibly innovating and featured electronic variable response turbocharging. If your OEM turbocharger is in rough shape, you can replace it with an OEM 2005.5-2007 Garrett GT3782 Stock Replacement Turbocharger.

Garrett Powermax Turbocharge for 04.5-07 6.0L Powerstroke

For those looking to upgrade their turbocharger, the 2004.5-2007 Ford Superduty 6.0L Powerstroke Garrett Powermax Turbocharger is a common upgraded turbocharger kit capable of supporting up to 175 horsepower over stock.

Hydraulic Rail Fuel Injection

Ford’s Superduty with the 6.0L Powerstroke V8 Diesel engine gained an updated fuel injection system. In this system, commonly referred to an a HEUI system, high-pressure engine oil helps compress diesel fuel. The Fuel injectors are controlled by a high-pressure hydraulic rail system that’s capable of delivering injection pressures of up to 26,000 psi. The result is a more powerful, efficient, and cleaner combustion.

Key Components of the Hydraulic Rail Fuel Injection System include:

  • Powertrain Control Module (PCM)
  • Injector Driver Module (IDM)
  • High-pressure Oil Pump (HPOP)
  • Injection Pressure Regulator (IPR)
  • Siemens Injectors

This system, while it did help significantly boost the 6.0L Powerstroke’s performance and helped reduce emissions, is actually a common failure point of these engines too.

Ford 6.0L Powerstroke V8 Diesel Engine Specs

Engine:6.0L Powerstroke V-8 Diesel Engine
Engine Design:Turbocharged V-8 Diesel
Engine WeightApproximately 966 lbs
Transmissions:5-Speed 5R110W Torqshift Automatic
ZF6 6-Speed Manual
Displacement:6.0 Liters or 365 Cubic Inches
Bore:3.74 inches or 95 mm
Stroke:4.134 inches or 105 mm
Block Material:Cast Iron Block
Connecting Rods:Powdered-metal
PistonsCast Aluminum
Cylinder Head Material:Cast Iron Cylinder Heads
4 valves per cylinder head
4 14mm head bolts per cylinder
Intake Manifold:Aluminum
Compression Ratio:18.0:1
Firing Order:1-2-7-3-4-5-6-8
Turbocharger/Air:Garrett VGT GT3782 TurboCharger, Air-to-Air Intercooler
Fuel Injection:HEUI, Hydraulic Actuated electronic unit
injectors
Valvetrain:OHV (Overhead Valve)
Single Cam, 32 Valve (4 valves per cylinder)
Engine Oil Capacity:15 Quarts with filter
Emissions DevicesEGR – Exhaust Gas Recirculation
Cooling System Capacity:27.5 Quarts or 8.75 Gallons.
Fuel:Diesel
Fuel Tank Size:29 Gallon or 38 Gallon Options
Horsepower:325 horsepower @ 3,300 rpms
Torque:2003-2004: 560 lb.-ft @ 2,000 rpm
2005-2007: 570 lb.-ft @ 2,000 rpm

Ford Superduty 6.0L Powerstroke Performance

There was a lot to be excited about with the introduction of the 6.0L Powerstroke V8 Diesel to the Ford F-250 and F-350 Superduty. For starters, the 6.0L Powerstroke engine gave the Ford Superduty a big increase in performance. 2003 Ford Superduty trucks with the 6.0L Powerstroke engine produce 325 horsepower and 560 lb.-ft of torque. When compared to the max figures of 275 horsepower and 525 lb.-ft of torque produced by the 7.3L Powerstroke, these were much needed performance gains. The 5.9L Cummins and the 6.6L LB7 Duramax were already posting figures that were vastly superior to those of the 7.3L Powerstroke as well, solidifying the need for an updated engine to stay competitive.

In addition to benefitting from the addition of a new, higher performance diesel engine, a new 5-speed TorqShift automatic transmission was also introduced. After being around for an extended period of time, this 5-speed automatic has proven itself to be quite reliable and capable of withstanding moderate performance upgrades.

These additions made the trucks drive smoother, made them more capable, and added to the max towing capacities of these trucks. It also aided these trucks in meeting federally mandated emission standards. Overall, the 6.0L Powerstroke allowed Ford’s Superduty to better compete with rivals thanks to the large jump in performance.

6.0L Powerstroke V8 Engine Bay Picture
6.0L Powerstroke V8 Diesel engine Bay Picture.

2003-2007 Ford Superduty Performance Comparison

The introduction of the 6.0L Powerstroke V8 Diesel engine made Ford more competitive against rival automakers GM and Dodge. How does it hold up against the other powertrains available within the Superduty lineup though? Check out how the 6.0L Powerstroke holds up against it’s fellow Ford Superduty powertrains in this chart down below.

Spec TypeTransmissionYearsHorsepowerTorque
5.4L V8 TritonAutomatic
Manual
2003-2004
2005-2007
260 horsepower
300 horsepower
350 lb.-ft
365 lb.-ft
6.8L V10 TritonAll Options2003-2004
2005-2007
310 horsepower
362 horsepower
425 lb.-ft
457 lb.-ft
6.0L Powerstroke V8 DieselAutomatic2003-2004
2005-2007
325 horsepower560 lb.-ft
570 lb.-ft
7.3L Powerstroke V8 DieselManual
Automatic
2003 Only275 horsepower
250 horsepower
520 lb.-ft
525 lb.-ft

Ford Superduty 6.0L Powerstroke Towing Capacity

The following Charts display max towing capacity for 2003-2007 Ford Superduty Trucks with the 6.0L Powerstroke V8 Diesel engine. Actual tow capacity for your vehicle can vary. Check your owner’s manual or Ford resources for exact towing capacity.

Manual Transmission F-250/F-350 Superduty SRW Towing Specs

Manual Transmission
Spec Types
YearF-250/F350
SRW Regular Cab
F-250/F-350
SRW SuperCab
F-250/F-350
SRW Crew Cab
Max Conventional
Tow Capacity 4×2
2003
2004
2005
2006
2007
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
Max Conventional
Tow Capacity 4×4
2003
2004
2005
2006
2007
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
Max 5th-wheel/Gooseneck
Tow Capacity 4×2
2003
2004
2005
2006
2007
13,600 lbs
13,600 lbs
16,400 lbs
16,400 lbs
16,400 lbs
13,300 lbs
13,300 lbs
16,100 lbs
16,100 lbs
16,100 lbs
12,900 lbs
12,900 lbs
15,900 lbs
15,900 lbs
15,900 lbs
Max 5th-wheel/Gooseneck
Tow Capacity 4×4
2003
2004
2005
2006
2007
13,300 lbs
13,300 lbs
15,900 lbs
16,000 lbs
16,000 lbs
12,900 lbs
12,900 lbs
15,600 lbs
15,600 lbs
15,600 lbs
12,700 lbs
12,700 lbs
15,400 lbs
15,400 lbs
15,400 lbs

Automatic Transmission F-250/F-350 Superduty SRW Towing Specs

Automatic Transmission
Spec Types
YearF-250/F350
SRW Regular Cab
F-250/F-350
SRW SuperCab
F-250/F-350
SRW Crew Cab
Max Conventional
Tow Capacity 4×2
2003
2004
2005
2006
2007
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lb
12,500 lbs
12,500 lbs
Max Conventional
Tow Capacity 4×4
2003
2004
2005
2006
2007
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
12,500 lbs
Max 5th-wheel/Gooseneck
Tow Capacity 4×2
2003
2004
2005
2006
2007
13,700 lbs
13,700 lbs
16,500 lbs
16,500 lbs
16,500 lbs
13,300 lbs
13,300 lbs
16,100 lbs
16,100 lbs
16,100 lbs
13,100 lbs
13,100 lbs
15,900 lbs
15,900 lbs
15,900 lbs
Max 5th-wheel/Gooseneck
Tow Capacity 4×4
2003
2004
2005
2006
2007
13,300 lbs
13,300 lbs
15,800 lbs
15,800 lbs
15,800 lbs
13,000 lbs
13,000 lbs
15,600 lbs
15,700 lbs
15,700 lbs
12,700 lbs
12,700 lbs
15,600 lbs
15,500 lbs
15,500 lbs

Manual Transmission F-350 Superduty DRW Towing Specs

Manual Transmission
Spec Types
YearF350
DRW Regular Cab
F-350
DRW SuperCab
F-350
DRW Crew Cab
Max Conventional
Tow Capacity 4×2
2003
2004
2005
2006
2007
13,300 lbs
13,400 lbs
15,000 lbs
15,000 lbs
15,000 lbs
13,000 lbs
13,000 lbs
15,000 lbs
15,000 lbs
15,000 lbs
12,800 lbs
12,800 lbs
15,000 lbs
15,000 lbs
15,000 lbs
Max Conventional
Tow Capacity 4×4
2003
2004
2005
2006
2007
12,900 lbs
13,000 lbs
15,000 lbs
15,000 lbs
15,000 lbs
12,600 lbs
12,600 lbs
15,000 lbs
15,000 lbs
15,000 lbs
12,400 lbs
12,400 lbs
15,000 lbs
15,000 lbs
15,000 lbs
Max 5th-wheel/Gooseneck
Tow Capacity 4×2
2003
2004
2005
2006
2007
13,300 lbs
13,400 lbs
16,400 lbs
16,600 lbs
16,600 lbs
13,000 lbs
13,000 lbs
16,300 lbs
16,100 lbs
16,200 lbs
12,800 lbs
12,800 lbs
16,100 lbs
16,100 lbs
16,100 lbs
Max 5th-wheel/Gooseneck
Tow Capacity 4×4
2003
2004
2005
2006
2007
12,900 lbs
12,900 lbs
15,900 lbs
16,100 lbs
16,100 lbs
12,600 lbs
12,600 lbs
15,800 lbs
15,600 lbs
15,800 lbs
12,400 lbs
12,400 lbs
15,600 lbs
15,600 lbs
15,600 lbs

Automatic Transmission F-350 Superduty DRW Towing Specs

Automatic Transmission
Spec Types
YearF350
DRW Regular Cab
F-350
DRW SuperCab
F-350
DRW Crew Cab
Max Conventional
Tow Capacity 4×2
2003
2004
2005
2006
2007
13,400 lbs
13,400 lbs
15,000 lbs
15,000 lbs
15,000 lbs
13,000 lbs
13,000 lbs
15,000 lbs
15,000 lbs
15,000 lbs
12,800 lbs
12,800 lbs
15,000 lbs
15,000 lbs
15,000 lbs
Max Conventional
Tow Capacity 4×4
2003
2004
2005
2006
2007
13,000 lbs
13,000 lbs
15,000 lbs
15,000 lbs
15,000 lbs
12,600 lbs
12,600 lbs
15,000 lbs
15,000 lbs
15,000 lbs
12,400 lbs
12,400 lbs
15,000 lbs
15,000 lbs
15,000 lbs
Max 5th-wheel/Gooseneck
Tow Capacity 4×2
2003
2004
2005
2006
2007
13,400 lbs
13,400 lbs
16,700 lbs
19,200 lbs*
19,200 lbs*
13,000 lbs
13,000 lbs
16,300 lbs
18,800 lbs*
18,800 lbs*
12,800 lbs
12,800 lbs
16,100 lbs
18,600 lbs*
18,600 lbs*
Max 5th-wheel/Gooseneck
Tow Capacity 4×4
2003
2004
2005
2006
2007
13,000 lbs
13,000 lbs
16,200 lbs
18,700 lbs*
18,700 lbs*
12,600 lbs
12,600 lbs
15,900 lbs
18,300 lbs*
18,300 lbs*
12,400 lbs
12,400 lbs
15,600 lbs
18,100 lbs*
18,100 lbs*
* max tow capacities with the * have the max tow capacity package featuring the 4.30LS Rear Axle Ratio.

2003-2007 Ford Superduty 6.0L Powerstroke History

2003 Ford F-350 Super Duty

2003 Ford Superduty 6.0L Powerstroke

In 2003, the 6.0L Powerstroke engine is introduced to Ford’s Superduty powertrain lineup. Producing 325 horsepower and 560 lb.-ft of torque, it was revolutionary and helped make Ford diesel trucks more competitive in the diesel market.

2004 Ford Superduty 6.0L Powerstroke

In 2004, the 7.3L Powerstroke V8 Engine is removed from the Ford Superduty powertrain lineup. Slight 6.0L Powerstroke modifications were made. 2004 models feature an updated turbo design, done to reduce sound.

2005 Ford Superduty 6.0L Powerstroke

In 2005, the 6.0L Powerstroke benefitted from. Max torque was improved to 570 lb.-ft, an improvement of 10 lb.-ft over last year’s model. Also, all super duty trucks for this year benefit from some chassis improvements that improved max payload towing capacity.

2006 Ford Superduty 6.0L Powerstroke

In 2006, Ford Superduty trucks get a large tow capacity increase in DRW models.

2007 Ford Superduty 6.0L Powerstroke

2007 marked the last year for the 6.0L Powerstroke engine. In 2008, it gets replaced by the 6.4L Powerstroke Engine.

Best Ford Superduty 6.0L Powerstroke Upgrades

Since the 2003-2007 Ford Superduty with the 6.0L Powerstroke V8 Diesel engine has been around for many years now, we’ve learned a lot about what can both improve their durability and lifespan, as well as what you can do to improve their performance. In this section of our guide we’ll explore what upgrades can be done to both make your truck last longer, and how you can increase horsepower, torque, and throttle response.

Top 6.0L Powerstroke Upgrades for Improved Reliability

6.0L Powerstroke Head Stud Upgrade Kit from ARP

ARP Head Stud Kit

If you’re going to add any performance modifications, or even if you just plan on towing frequently, the addition of an ARP 6.0L Powerstroke Head Stud Kit is a must-have upgrade! The TTY head bolts are known to stretch, resulting in a blown head gasket.

Mishimoto Coolant Filtration Kit

Coolant breakdown due to the EGR process is a frequent contributor to 6.0L Powerstroke failure. Keep your coolant and engine components cleaner with this simple upgrade that won’t break the bank! Check out the Mishimoto Coolant Filtration Kit.

Mishimoto Coolant Filtration System
Edge Insight CTS3

Edge Insight CTS3

One of the best upgrades for any truck is a performance monitoring system. Performance monitors like the Edge Insight CTS3 provide real-time data and allow you to monitor critical engine parameters like Coolant and Oil temp simultaneously. This makes spotting things like a plugged oil cooler significantly easier. If you’re also interested in tuning, you can opt for the Edge Evolution CTS3 instead which gives you the benefits of a performance monitor and a tuner all in one! Check out our Edge Insight CTS3 review here!

Top 6.0L Powerstroke Performance Upgrades For Improved Power

The 6.0L Powerstroke comes from the factory producing 325 horsepower and 560-570 lb.-ft of torque. While these numbers were incredible at the time, these are only a fraction of what modern-day diesel engines like the latest 6.7L Powerstroke engine can churn out. Fear not, however, there are a multitude of aftermarket solutions that can improve 6.0L Powerstroke Performance, fuel economy, and throttle response dramatically! Check out some of our favorites down below.

Edge Evolution CTS3 6.0L Powerstroke

Edge Evolution CTS3

If you want the real-time performance monitoring and tuning all in one unit, the Edge Evolution CTS3 is one of the latest, and most capable box tuners available for the 6.0L Powerstroke. Get power gains of up to 100 horsepower and 200 lb.-ft of torque. It also helps improve fuel economy and throttle response! It’s also CARB and emissions compliant!

Banks Ram Air Intake

Cold air intakes are an excellent and inexpensive performance upgrade for any diesel truck! The 6.0L Powerstroke is no exception. If you’re familiar with diesel performance, than you know who Gale Banks is. Bank’s Performance builds the 6.0L Powerstroke Bank’s Ram Air Intake that improves air flow up to 38% and helps bring in cooler, denser air.

Banks Ram Air Intake 6.0L Powerstroke

Banks Intercooler Upgrade

Maintaining lower coolant, engine oil, and exhaust gas temperatures is absolutely critical on the 6.0L Powerstroke engine. Factory intercoolers feature plastic end tanks and vastly inferior performance. Check out the Banks Power Intercooler Upgrade. 03-04 Powerstroke needs the Banks Power Intercooler Upgrade Kit #25974. 05-07 Powerstrokes need Banks Power Intercooler Upgrade Kit #25975.

For more 6.0L Powerstroke upgrades, visit our post, The Best 6.0L Powerstroke Powerstroke Upgrades.

Most Common 6.0L Powerstroke Problems

6.0L Powerstroke Head Stud Upgrade Kit from ARP

Head Gasket Failures Caused by TTY Head Bolts

6.0L Powerstroke engines come from the factory with only four, 14mm Torque-to-Yield (TTY) head bolts per cylinder. Putting these trucks under high load, or increasing cylinder head pressures due to performance modifications can quickly cause the factory TTY bolts to stretch. This significantly reduces their clamping pressure, resulting in a blown head-gasket. By upgrading to ARP Head Studs, you can remove these underperforming TTY head bolts and save yourself from the headache of a blown head gasket.

Oil Cooler

One of the most common 6.0L Powerstroke problems is a failed oil cooler. When this Powerstroke’s oil cooler fails, it causes oil temperatures to jump drastically. This occurs due to build up in the coolant passageways that accumulates overtime. Once this occurs, it’s time for a new Engine Oil Cooler. Ford’s OEM Replacement Oil Cooler is an option, or you can opt for an aftermarket solution like the PPE Heavy Duty Oil Cooler upgrade kit.

6.0L Powerstroke Oil Cooler Upgrade from PPE

EGR problems

Exhaust Gas Recirculation was first introduced to Ford diesels with the 6.0L Powerstroke. As with anything new, especially emissions devices in automobiles, there were plenty of kinks that needed to be worked out. If your EGR goes out, consider buying a significantly better quality Bulletproof Diesel EGR Cooler. Carefully select the one you need your truck because there are different models between model years.

While I only included three problems that are frequently encountered with this engine in this post, there are actually many more problems that can occur. Check out our comprehensive guide with the most common 6.0L Powerstroke problems and how to fix them in our Most Common Ford Superduty 6.0L Powerstroke Problems post.

2003-2007 Ford Superduty 6.0L Powerstroke Maintenance

One of the best ways to make your 6.0L Powerstroke more reliable is by properly maintaining your truck. Due to the EGR process, your system’s coolant and engine oil are under significantly more strain, especially if your truck is used for heavy towing, or if it’s modified with aftermarket products like tuners. Even stock trucks that operate under minimally harsh conditions experience problems at some point. That’s why it’s absolutely critical you perform 6.0L Powerstroke maintenance frequently, and that you use the best fluids, oil, and filters possible.

In this section, we’ll provide a brief overview of how to maintain your 6.0L Powerstroke-equipped Ford Superduty truck.

Ford Superduty 6.0L Powerstroke Diesel Truck

6.0L Powerstroke Service Intervals

One of the most important things to keep in mind when it comes to 6.0L Powerstroke maintenance is that just because of your truck’s engine design, we recommend following the severe maintenance schedule. It requires more frequent service, but your truck will thank you for it. It’ll help keep your truck on the road for a longer period of time.

Maintenance/Service TypeMilesKilometers
Change Oil5,000 miles8,000 km
Change Oil
Filter
5,000 miles8,000 km
Change Fuel
Filter(s)
10,000 miles16,000 km
Replace Air
Filter
Check Filter restriction
gauge. Replace
as necessary.
Check Filter restriction
gauge. Replace
as necessary.
Flush Cooling
System
Every 40-50,000 miles
or once every 1-2 years.
64-80,000 km or
once every 1-2 years.
Replace Auto
Transmission
Fluid
30,000 miles48,000 km
Replace Manual
Transmission
Fluid
60,000 miles96,000 km
Change External
transmission filter
30,000 miles48,000 km
Change internal
transmission filter
30,000 miles48,000 km
Replace Transfer
Case Fluid
150,000 miles/ 60,000 miles under
severe operating conditions
240,000 km/96,000 km under
severe operating conditions.
Replace Rear
Differential Fluid
100,000 miles/ 30,000 miles under
severe operating conditions
160,000 km/ 48,000 km under
severe operating conditions
Replace Front
Differential Fluid
100,000 miles30,000 miles under
severe operating conditions
160,000 km/ 48,000 km under
severe operating conditions

2003-2007 Ford Superduty 6.0L Powerstroke Fluid & Oil Capacity

Oil/FluidCapacity – QuartsCapacity – Liters
Engine Oil15 Quarts /w filter14.2 Liters
Auto Transmission Fluid17.5 Quarts16.6 Liters
Manual Transmission Fluid5.8 Quarts5.5 Liters
Transfer Case2 Quarts1.9 Liters
Engine Coolant27.5 Quarts26 Liters
Front Differential Fluid
(Dana 60)
3 Quarts2.8 Liters
Rear Differential Fluid
Sterling 10.50″
Dana 80
Dana S110
Dana S130
See Below
3 Quarts
3.5 Quarts
6.98 Quarts
6.98 Quarts
See Below
3.3 Liters
4.0 Liters
6.6 Liters
6.6 Liters

2003-2007 Ford Superduty 6.0L Powerstroke Oil, Fluids, and Maintenance Parts

6.0L Powerstroke Engine Oil

Engine oil typeOutdoor Ambient TemperaturePart #
Buy it on Amazon
Part #
Buy it at Walmart
SAE 15W40Acceptable at temperatures
over 10 degrees Fahrenheit.
Recommended Oil for temperatures
over 30 degrees Fahrenheit.
Motorcraft XO-15W40-5Q3SDMotorcraft XO-15W40-5Q3SD
SAE 10W30Preferred engine oil at temperatures between
30 to -10 degrees Fahrenheit.
Acceptable at temperatures
from -10 to 90 degrees
fahrenheit.
Motorcraft XO-10W30-5Q3SDMotorcraft XO-10W30-5Q3SD

6.0L Powerstroke Filters And Fluids

Part TypePart #
Engine Oil FilterFord: 3C3Z-6731-AA
Motorcraft FL-2016
Oil Filter CapFord: 3C3Z-6766-CA
Motorcraft EC-781
Fuel FilterFord: 3C3Z-9N184-CB
Motorcraft FD-4616
Engine Air FilterFord: 4C3Z-9601-AA
Motorcraft FA-1778
CoolantConcentrated : Motorcraft VC-7-B
Diluted: Motorcraft VC-7-DILB
Automatic Transmission Fluid
For TorqShift 5R110W Trans
Motorcraft Mercon SP ATF
Manual Transmission Fluid
For ZF
Motorcraft Mercon V
External Transmission 
Filter
Motorcraft FT-145 
(Re-Use your O-Ring)
Internal Transmission 
Filter
Motorcraft FT-144
Transfer Case FluidMotorcraft Mercon V
Front Differential FluidMotorcraft SAE 80W-90 Premium Rear Axle Lubricant
XY-80W-90–QL
Rear Differential Fluid
Sterling 10.50″
Dana 80
Dana S110
Dana S130
See Below *(May need to add Additive)*
Motorcraft SAE 75W-140 XY-75W140–QL 
Motorcraft SAE 75W-90 XY-75W90–QLS
Motorcraft SAE 75W-140 XY-75W140–QL
Motorcraft SAE 75W-140 XY-75W140–QL

Looking for more Ford Superduty 6.0L Powerstroke Maintenance Information? Visit our Comprehensive Ford Superduty 6.0L Powerstroke Maintenance Guide.

2003-2007 Ford Superduty 6.0L Powerstroke FAQs

Is the 6.0L Powerstroke a good engine?

The 6.0L Powerstroke V8 Diesel engine was revolutionary when it was released in 2003 in Ford Superduty trucks. Boasting 325 horsepower, 560 lb.-ft of torque and featuring an advanced variable geometry turbocharger, it offered significantly greater performance than the outgoing 7.3L Powerstroke. Despite its impressive performance characteristics, this engine has a myriad of engine flaws and design issues that make them unreliable and problematic in many cases.

How much oil does a Ford Superduty 6.0L Powerstroke take?

Ford Superduty trucks with the 6.0L Powerstroke diesel engine require 15.0 quarts of oil, including the filter.

What oil does a Ford Superduty 6.0L Powerstroke require?

Most Ford Superduty F-250/F-350 owners who have the 6.0L Powerstroke Diesel engine will use Motorcraft SAE 15W40(Motorcraft XO-15W40-5Q3SD). If you are in a cooler climate, you may require different engine oil. See our maintenance section for more information.

What year was the 6.0L Powerstroke released in Ford Superduty Trucks?

The 6.0L Powerstroke made its debut in 2003 in Ford Superduty Trucks. It was available until the 2007 model year. In 2008, Ford replaced the 6.0L Powerstroke with the 6.4L Powerstroke V8 Diesel Engine.

How much does it cost to bulletproof a Ford Superduty 6.0L Powerstroke?

Bulletproofing a 6.0L Powerstroke can thousands of dollars. Depending on the degree of bulletproofing you are undertaking, the parts and labor can reach up to $10,000-$15,000 to make a perfect 6.0L Powerstroke.

Who made the 6.0L Powerstroke?

International Navistar built the 6.0L Powerstroke engine for Ford. Ford used the 6.0L Powerstroke engine in their Ford Superduty Trucks, the Excursion, and also the Ford E-series vans.

Check Our Other Ford Superduty 6.0L Powerstroke Posts

Article Sources
  • 2003 Ford F-250, F-350 Super Duty Brochure, Ford Motor Company, 2002. 
  • 2004 Ford Superduty Brochure, Ford Motor Company, 2003. 
  • 2005 Ford Superduty Brochure, Ford Motor Company, 2004. 
  • 2006 Ford Superduty Brochure, Ford Motor Company, 2005. 
  • 2007 Ford Superduty Brochure, Ford Motor Company, 2006. 
  • “The 6.0L Power Stroke Engine.” Powerstroke Diesel, Ford Motor Company, powerstrokediesel.com/engine6.0. Accessed 25 Sept. 2023. 

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