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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