Ford Powerstroke 03-07 6.0L Discussion of 6.0 Liter Ford Powerstroke Turbo Diesels

Ok I have a 04 powerstroke that died after it was up to operating temp

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Old 05-24-2014, 10:52 PM
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Default Ok I have a 04 powerstroke that died after it was up to operating temp

So this 6.0 that I now own and have never turned a wrench on died on me the first day it was on the road start cold dies when warm the typical deal I have pulled the hpop out waiting for seals and gaskets is there any other seals, gaskets, orings I should replace that could cause this issue?? I am tryng to make this a one time deal the truck has 260k straight exaust and a cold air intake if these make any difference to the diagnosis please help I am new to the 6.0 I can work on 7.3 all day but this seems to be a new ball game to me
 
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Old 05-25-2014, 12:05 PM
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What year is it?

If it's an 05-07, the most likely high pressure oil system leaks will be a leaky STC fitting, or the stand pipes and dummy plugs.
It could also need new injector o-rings or high pressure oil rail o-rings.

This could add up to quite a bit of work in the end, but, with as many miles as you have, this would be a good time to do all of them.

Do you know if any of this work has been done before?
 

Last edited by bustedknuckles; 05-25-2014 at 12:12 PM.
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Old 05-25-2014, 03:26 PM
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The truck is an early 2004 no stc fitting I asume the past owner was chasing this problem as they have replaced the turbo a few injectors and the egr valve the hpop looks really clean for that many miles however I'm not sure that it's new the oil seals are rock hard
 
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Old 05-25-2014, 04:43 PM
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Since mine is an 06 (05 build), I've not studied or seen all the o-rings in your model engine, however, I know any one of the o-rings in the high pressure oil system can cause poor starting and bad running. I also have an opinion that they should all be replaced after a significant number of miles, number of years (regardless of number of miles), and if the engine has experienced an overheating incident (regardless of miles or years of service).
Since you bought the truck used, you probably don't know everything that happened to it, but it sounds like you realize the importance of replacing all the o-rings in yours, given the miles.
You can get the oil rail o-rings, including both sides of the nipples (one of them goes in the injector) for about $30. The orings that go in the injector are the ones that seem to be one key, when it comes to re-building the injectors. Ford does not sell these particular o-rings because they want people to buy rebuilt injectors from their Autolite division.
 
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Old 05-25-2014, 05:10 PM
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You can buy all the Orings on Ebay, they are OE parts too. in fact the early 04 and 03 trucks have 5 STC fittings on them but are not as prone to failure as the 05 and up.
Make sure you have a factory oil filter cap and either a Motorcraft or Fram oil filter, they are exact same. Some of the after market FILTERS ARE TOO SHORT AND WILL CAUSE OIL STARVATION due to the fact the filter is too short to hold down a small "drain back" plunger at the bottom of the filter housing.
On the 04 the most common Oring failure are the top of injectors and the Big Orange Oring that sits on to of the nipple of the branch tube connector, this nipple is the port that supports the operation of both the IPR valve and the ICP sensor. it can get damaged because you have to slip the cast iron cover over it and it can get nicked.
The worst case scenario for any High pressure oil leak is a cracked branch tube.
An AIR TEST will really help find the source of the HPoil leak, it is the best test to do.
 
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Old 05-25-2014, 10:11 PM
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I am replacing all the hpop orings to start with and I have to replace the valve cover seals how dose the oil feed into the injectors on the 6.0 I know in the 7.3 the rail is internal also if the branch tubes are leaking how do I remove them I order to replace them it looks a real pain
 
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Old 05-25-2014, 10:56 PM
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on the 6.0 the High Pressure oil rail actua;;y sits right on top of the injectors, there is an Oring in top of injector and the is also a oring for the nipple that sticks out of Hp oil rail, there is a special tool to remove the nipple to replace those orings.
As far as replacing the branch tube the easiest way is to pull the motor. The heads have to come off as well as the adaptor plate/rear engine cover. you could pull the trans and then the heads while the motor is still in but that is a major pain, I personally like to pull the motor, a lot less expensive then pulling the cab because you don't have to mess with the brakes or AC system, plus if you have ever pulled a V8 motor before it is all the same. I can have a motor out in about 6 hours using an engine lift I bought at Harbor freight. the other good thing is when the motor is out you can pull the oil pan to make sure it is clean, you will almost always find the ends of Tywraps in there, either from injectors or glow plug connectors. since you have to pull the heads it is a perfect time to do headstuds and new Ford head gaskets.
 
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Old 05-25-2014, 11:02 PM
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Well I think with all the new knowledge I will replace the hpop orings and the injector orings and cross my fingers I can't afford to have the truck down much longer
 
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Old 05-27-2014, 03:33 PM
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Do an airtest!!! It can save you a lot of time and money!!! You can also run the truck with out the valve covers to see if the oil rail is leaking around the nipples but I doubt that is your problem and a lot of work to run it like that. I would start with dummy plugs and stand pipes and if you have the HPOP cover off the oil rings in there if you are going to be throwing parts at it. I have a 04 too. No STC fitting but the same stand pipes and dummy plugs the 05+ have and the wavy style oil rail.
 
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Old 05-27-2014, 08:21 PM
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he has the early 04, "LOG" style oil rails, no dummy plugs and the stand pipes are totally different, the oil rails are connected to the stand pipes via a braided hose with STC fittings on either side of them.
 


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