| 6.0L’S HAVE PROBLEMS – WE’VE GOT ANSWERS | |||
| 2003 | |||
| COMMON PROBLEM/FAILURE: | CAUSE: | SOLUTION: | PART NUMBER: |
| Turbo failure | 1) Restrictive oil drain tube | Upgraded oil drain tube from Ford | PN 6C3Z-9T515-A |
| (VGT vanes sticking) | 2) Lack of internal turbo groove | Replace turbo | Use ’07 turbo |
| Leaking oil under turbo | Bad ICP sensor | Replace ICP sensor | PN 3C3Z-9F838-EA |
| FICM-related rough idle | Problematic pilot injection feature | Reflash FICM (by application) | PN Need VIN |
| 2004 | |||
| COMMON PROBLEM/FAILURE: | CAUSE: | SOLUTION: | PART NUMBER: |
| EGR cooler (late ’04) | Restrictive rectangular design | Replace or clean EGR cooler | PN 4C3Z-9P456-AF |
| Turbo failure | 1) Restrictive oil drain tube | Upgraded oil drain tube from Ford | PN 6C3Z-9T515-A |
| (VGT vanes sticking) | 2) Lack of internal turbo groove | Replace turbo | Use ’07 turbo |
| 2005 | ||||
| COMMON PROBLEM/FAILURE: | CAUSE: | SOLUTION: | PART NUMBER: | |
| EGR cooler | Restrictive rectangular design | Replace or clean EGR cooler | PN 4C3Z-9P456-AF | |
| Turbo failure | 1) Restrictive oil drain tube | Upgraded oil drain tube from Ford | PN 6C3Z-9T515-A | |
| (VGT vanes sticking) | 2) Lack of internal turbo groove | Replace turbo | Use ’07 turbo | |
| HPOP leaking oil | STC connector fails | Replace STC connector | PN 4C3Z-9B246-D | |
| Oil rail plug(s) leaking oil | O-rings fail | Replace oil rail plug | PN W302195 | |
| 2006 | |||
| COMMON PROBLEM/FAILURE: | CAUSE: | SOLUTION: | PART NUMBER: |
| EGR cooler | Restrictive rectangular design | Replace or clean EGR cooler | PN 4C3Z-9P456-AF |
| Turbo failure | Lack of internal turbo groove | Replace turbo | Use ’07 turbo |
| Oil rail plug(s) leaking oil | O-rings fail | Replace oil rail plug | PN W302195 |
| 2007 | |||
| COMMON PROBLEM/FAILURE: | CAUSE: | SOLUTION: | PART NUMBER: |
| EGR cooler | Restrictive rectangular design | Replace or clean EGR cooler | PN 4C3Z-9P456-AF |
| Oil rail plugs | O-rings fail | Replace oil rail plug | PN W302195 |
| 2003 – 2007 (ALL MODEL YEARS) | |||
| COMMON PROBLEM/FAILURE: | CAUSE: | SOLUTION: | PART NUMBER: |
| EGR valve sticking (’03 to early ’04) | Carbon, soot buildup | Replace or clean EGR valve | PN 4C3Z-9F452-A |
| EGR valve sticking (late ’04 to ’07) | Carbon, soot buildup | Replace or clean EGR valve | PN 53Z-9F452-AA |
| Blown head gasket | Head bolts stretch | ARP head studs, H-11 head studs | PN 250-4202 (ARP) PN1300-5001 (Elite) |
| Oil cooler | Plugged or gasket failure | Clean oil cooler and/or replace gasket | PN 3C3Z-6A642-AA |
| Sticking spool valve in injector | Stuck spool valve (open/closed) | Inductive Heating Flash – FICM | PN Need VIN |
| Cracked IC boot (’03 to early ’04) | Wear, heat | Replace boot | PN 6C3Z-6C640C |
| Cracked IC boot (late ’04 to ’07) | Wear, heat | Replace boot | PN 6C3Z-6C640A |
| Coolant leak | Degas bottles crack on seams | Replace degas bottle | PN 6C3Z-8A-O8OB |
| FICM calibration(s) | Bad calibration, fried circuit board | Re-flash or new FICM | PN Need VIN |
| Injector harness wear | Chafed wiring harness | Replace wiring harness (by application) | PN Need VIN |
| FICM harness wear | Chafed wiring harness | Replace wiring harness (by application) | PN Need VIN |
Give us a call here at Roadmaster Engine World if you need engine parts for this Ford 6.0L diesel or a Ford 6.0L remanufactured engine.
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