6.0 Nightmare
 

Bought an '03 F-350 with the sik-o engine. At the time it needed a FICM and for the price, I could replace the whole engine and come out ahead by selling the truck at book. Replacing the FICM took care of the issue, but I have been trained by an International Truck dealer on these engines and we have multiple [flawed] procedures for working on these. #1, when a cooler goes, you replace it. period. no further checking or testing. fix and release. #2, we never pull the oil cooler for a look-see without it being a suspect of failure. #3, we don't even stock the HPOP screen, but all that's besides the point.

My EGR cooler hatched into a disaster last week when it completely let go and drained my coolant system into the intake. Unfortunately this adversely affected the cylinders and by hydraulic forces, pushed a chunk of head gasket out. Upon pulling the oil cooler to inspect, it was 80-85% plugged. All 8 screen elements were completely missing, and the oil cooler cavity was filled with unidentifiable crap.

I will be replacing the HPOP and IPR, the HPOP screen, the oil cooler will be replaced by a BPD oil cooler mod kit, the EGR will be replaced by a BPD cooler, the head gaskets will be replaced and I will be using ARP Head studs to reassemble. Does anybody have any other suggestions of thing I should check/replace/repair while i have the engine out? I also plan on doing the branch tube while everything is apart. Any and all suggestions are welcomed. First time I have had the freedom to do what I want with a six uh-oh and Im like a kid in a candy store, despite being out my truck for a month and all the money im putting in the thing. When i get it all done, im hoping i wont ever have to dip into it again. By eliminating the weak points, I think the 6.0 could be as indestructable as the old DT360 International! lol

Thank Guys!

I was laughing when I read your post... Mechanics not changing the oil coolers when changing the EGR is one of the reasons the 6.0 has gotten such a bad wrap... Although, I do understand you were just explaining. How the MAN directs you to fix it. 03 & 04 is a good candidate for stand pipes and dummy plugs while you are right there.

Make sure you get the head checked, for flatness and pressure test the fuel rail in the head. Only use stock Ford/or international head gaskets, the black ox ones will fail in a year which is very common. I would delete the EGR cooler if you can where you live, if its just a visual inspection for emmisions just weld in a 35mm freeze plug into the exhaust end of cooler and a 30mm on the intake side. that way the cooler is there but it will never fail on you, you can even use the old cooler.
The last and most important thing to do is to put a coolant filter on it when you get it all together, the loose sand from the sandcast is what causes the coolers to clog.
Also keep in mind that the FICM can be repaired for under $200, it's the solder joints that fair and can be repaired so they are better than new and will last a whole lot longer, the problem is with the environmentally friendly solder they use.

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03 and 04s don't have dummy plugs, If you order the head gaskets from ford they will come with new standpipes for the year you order.

Exactly what Bob said...

sounds like a good plan. Just make sure you have the heads done at a reputable machine shop, preferably one that has done 6.0 heads before. OEM head gaksets only.