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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