Ford 2003 to 2007 Superduty has been one of my favorite diesel pickups for many years. Even today, I see many versions of diesel pickups roaming on the roads or waiting in the parking for their owner to come and take them home.
No doubt- these are special children of diesel fitters and need special attention. You can enjoy a powerful ride across the city by giving them the required attention.
Before diving into the best modifications in the 6.0 power stroke to improve its performance, we will discuss some basic information, such as what the Ford 6.0 Powerstroke is, its history& evolution.
The article will also give you a slight comparison with its predecessors, and what you must keep in mind before modifying the engine.
Let’s get started!
What is 6.0 Power Stroke?
For those who don’t know, a 6.0 power stroke is a heavy-duty truck engine that works on the powerstroke principle- high-pressure created by the heat of compressed air of diesel that pushes down the piston.
Ford used the 6.0 powerstroke engine from 2003 to 2007 in its pickup trucks with upgrades on its model year. Moreover, this power stroke engine was also used till 2010- when the company installed it in the Ford Excursion SUVs and Ford Ecoline vans.
These powerful engines come with one of the best fuel efficiency in the market. When you have one, you don’t need to worry about the fuel efficiency and towing capacity.
The fuel efficiency varies between 13 to 18 mpg, and the maximum towing capacity is 15,000 pounds.
It is also known as “Six Point Blow“ because of its ability to blow the head gasket- which is quite impressive, right?
History and Evolution of 6.0 Power Stroke
After the execution of diesel engine emission standards in January 2003 by authorities to eliminate smoke from the environment, Ford and International knew they had to be on the safe side of the line by investing money in their 7.3 engine to keep it in the market. Otherwise, the authorities won’t let them work, or they will face penalties.
With this in mind, the company takes the suggestions and tries to add a higher pressure injection system, EGR, and a variable geometry turbo in their existing 7.3 engine. The problem with this upgrade was the horsepower disadvantage on which competitors like Duramax and Cummins are already working.
So, Ford and International- in their joint venture, came up with a brand new 6.0 Powerstroke engine following all the smog safety standards.
The company presents a new powerful engine with a noise reduction feature, Exhaust Gas Recirculation, four valves per cylinder, variable geometry turbo technology, and improved fuel economy- the Ford’s 6.0 Power Stroke.
It was a complete package for anyone looking for an engine with great towing capacity and increment of horsepower.
This engine keeps an end to the life of the 7.3 diesel engine that gave rise to the era of the 6.0 Power Stroke in 2003.
Why does 6.0 Power Stroke Need Modifications?
This engine passes all the performance tests and must not be a problem for a consumer from a manufacturer’s point of view. At the same time, the consumers point out some of the pain points that need to be addressed.
Here we are listing a few problems from the consumer’s point of view,
- The exhaust gas recirculation (EGR) cooler failed as a coolant and produced white smoke due to the problem with the head gasket.
- The oil cooler suspends the coolant in the tight passageways.
- The turbocharger problem is due to oil starvation or contamination.
- The sticking turbo problem causes the loudest whistles sound variable geometry of the GT3782VA.
We have gone beyond the 6.0 power engine-specific problems and offer reliable solutions that will not affect your engine performance as some amateur diesel engineers did.
Considerations Before Modifying
We can do as many modifications as you want to make your Powerstroke engine work on your commands.
To do so the foremost thing you need to follow is to put together a to-do list. This list will help you pinpoint what you need and how to move further with the MODs.
Jot down your purpose for this modification, and brainstorm what you want to do with your truck, is the purpose to increase the towing capacity or do you want to improve its airflow to avoid hefty parts replacements in the future?
This list will help you more than anything in building an updated 6.0 Power Stroke Engine.
Another thing you must keep in mind is- the Power Stroke Engine Model Year. Engine models are different based on their model years. The parts are different such as the head bolt size, injectors, front covers, and glow plugs.
If you want to replace a part, prior knowledge of your engine model will help you arrange your part fast. Also, if the engine modifier is not you, discuss your case with an expert mechanic of 6.0 Power Stroke and get professional help.
One more thing you need to consider here is the cost- the engine came before the DPF system and there is no such filtration system in these trucks, so the price for the upgrade will eventually rise.
However, as we all know if the ends well, all is well, the engine will justify every single penny cost with its performance. So, don’t take it on your nerves.
The Best 6.0 Power Stroke Performance MODs
The common problems in the power stroke models are turbo failure, coolant blockage, the Variable Geometry Turbo van sticking, FICM-related issues, and more.
To solve all the issues, we are stating some of the modifications you can do in the 6.0 power Stroke engine and the solutions will blow your mind.
Airflow Upgrades
The improved airflow is one of the required upgrades for this diesel engine- even if it is not causing a problem.
You can improve the airflow of the engine by improving the turbocharge efficiency. Improving turbocharge efficiency keeps stress off the turbocharger and frees up power.
You can add a tune that boosts your engine’s turbocharger level which in return needs more air to compensate. With it, the engine will not require more power to reach the intended boost level.
5-12 horsepower grains, a fast turbo spool, and the extra roar are the key features you can get by improving the airflow.
Turbo Upgrades
If you are looking for 500rwhp from your truck, you can get it by improving your turbocharger. Multiple turbochargers are available in the market based on your model year.
According to the diesel fitter, a market-available turbocharger can produce 475rwhp- with the upgrades, it can run between 500rwhp and 800rwhp.
Always go with a more powered turbocharger than you intended to install. For example, if you need a turbocharger with a capacity of 700rwhp, install the one with the 800rwhp. That way, you won’t stress your engine running at full capacity
Coolant Upgrades
One of the most reported problems in the Ford 6.0 Power Stroke is coolant blockage in the system. The root cause behind the problem is the restrictive regular design of the engine.
The engine works on the liquid-to-liquid heat exchanger model. Over time, the dust accumulates in the system. That accumulated dirt with the coolant winds up and blocks the tight passageways- which causes ultimate blockage.
Many companies are producing Ford’s Power Stroke cooler filtration systems. Installing them can solve your problem and protect your investment. Other than that, you can also clean the system routinely or replace the EGR cooler.
Simple Solutions for Major Problems
- The problematic pilot injection features cause the FICM-related issues- you can solve them by reflashing the FICM.
- The van sticking problem is due to the lack of an internal turbo groove. You can improve it by replacing the turbo.
- The bad ICP sensor causes the leaking oil under the turbo- you solve your problem by replacing the ICP sensor.
- The restrictive oil drain tube is the cause of turbo failure. You get rid of it by upgrading the oil drain tube purchased from the Ford.
Performance Gains from Modifications
With these upgrades, you can enjoy multiple benefits. Here are the performance gains you can get by upgrading your engine.
- You can improve your engine health and power output by improving the airflow.
- You can improve your wheel horsepower between 500rwhp-800rwhp by upgrading the turbocharger based on your engine model.
- By resolving the coolant blockage issue, the elevated engine temperature will decrease and this will improve the heat exchange efficiency of your engine.
- By reflashing the FICM, the spool valve will release the correct amount of high-pressure valve into the injector, and the FICM-related issues will be resolved.
- You can avoid the oil sticking problem and turbocharger failure by replacing the turbo.
- The new ICP sensor will sense the pressure of the oil feeding the injector and improve your vehicle’s performance.
- The brand-new turbo tube will solve the oil drain problems and avoid turbocharger failure.
These modifications can improve your truck’s engine performance without making a large hole in your pocket. Every problem has a solution, all you have to do is, find it. Find your engine problem, hit the target area, modify or replace the particular part, and transform your engine with the right implementation.
Keep Running Your Ford
The Ford 6.0 Power Stroke has been the talk of the town for some unfortunate reasons in the diesel industry from the time of its release that it doesn’t deserve.
I know there are areas of improvement, such as ICP sensor issue, FICM-related issues, decreased horsepower, and the torque -but why does one always forget about the variable geometry turbocharger, 5-speed Torqshift, iron bedplate head gasket, and externally accessible glow plugs?
With no exemption to the Ford 6.0 Power Stroke, there is no machine- no upgrade policy in the world. Every machine needs time-to-time upgrades, repairs, parts replacements, and maintenance.
You can also improve America’s number one heavy-duty truck performance by installing a filtration system, upgrading a cooler system, improving airflow, reflashing FICM, replacing turbo tubes, and exhaust upgrades- to mold it to the way you want.
Let your 6.0 Power Stroke engine outsmart all the latest engines with these simple moderations and on the road like the latest Ford Power Stroke Engines.
