REVIEW: Everything Wrong With a 6.0 Powerstroke

What could possibly be wrong with the Ford 6.0 Powerstroke #diesel engine?

We cover all the common problems with the Ford 6.0 Powerstroke / Navistar VT365 diesel engine, discuss design issues, serviceability, downtime costs, EGR, horsepower and torque, and compare it with various engines you might consider including the 5.9 Cummins ISB CR, 6.6 Duramax, and of course the 7.3 Powerstroke. #RichReviews #EWWengines #AnsellProtects #PoweredtoProtect

Big thanks to Tewsley Auto Parts & Recyclers for the 6.0!

How To Videos referenced:

0:00 Everything wrong with a 6.0 Powerstroke
2:02 Design issues
3:37 Disassembly
5:33 Sponsor - Ansell Gloves
6:32 Map sensor
6:46 Injection Control Pressure sensor
8:21 EGR valve jammed with soot
9:23 Fuel line removal for intake access
11:32 Intake to front cover o-ring
12:13 IPR Valve failure
13:30 HPOP - high pressure oil pump leak
14:30 LPOP - low pressure oil pump walk
14:43 Oil cooler cracks
16:33 Updated oil cooler filter screen
16:45 Stand pipe and dummy plug
18:16 High pressure oil rail ball tube & seal leak
18:33 Diesel fuel injector leak
19:19 Head gaskets
20:16 HPOP o-rings
21:42 HPOP failure
22:01 Exhaust back pressure sensor
23:37 Misfire diagnosis
24:06 Rocker arm assembly
24:19 Head disassembly
26:22 Cost of ownership
27:35 Vehicle platform years
28:17 Buying tips
29:21 Conclusion

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411 Darling Rd, Canfield, ON Canada N0A 1C0

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[DEBOSSGARAGE]

Thanks to Tewsley Auto Parts for hooking us up with this 6.0 to tear down! What engine should we review next?
If you need more help with your 6.0 Powerstroke, you're gonna want to check out these channels:
@DieselTechRon (RIP)
@FordTechMakuloco
@Powerstrokehelp

[mikeznel]

I like this guy. He takes this seriously and uses the proper terms and doesn't confirm if he isn't completely sure.

[Lou-jenh]

i loved the 6.0's, we had at least 2 in the shop at any given time. They kept us busy and made lots of money.

[seanmccready]

Gotta hand it to Rich on this one. He does a great job of maintaining that careful balance of engagement with the person he’s working with, without stepping all over them, and also not being distracting, or cutting into any cheese factors, trying to be the star of the show all the time or anything else like that.

Not easy to do. Very few media personalities in any medium can work like that with other people and have it be so natural and work well. Props from deep in the BC rocky mountains!

[brianherndon]

Props to Ford for making an engine look cramped even when out of the vehicle

[jesselong]

This guy is a fleet managers goldmine. Eight yrs of 6.0 work makes him worth a ton. Someone gonna see this and make him an offer. Thanks for content

[chodickson]

'I don't know how the [egr] delete kit works". That's the exact answer I tell strangers too.

[ks_]

Who else kinda misses diesel tech ron's videos after seeing his name come up ? RIP Ron

[ziptiesnbiasplies]

I figured this was gunna be a nine hour Vidya! Hahahah

[cnf]

Today I had a 6.4 in the shop. Hopped in, no obvious deletes, no tuner, and 324, 000 miles…I was absolutely baffled…so I pulled it into the shop like ‘this is unbelievable…wait…lemme check something…’ so I popped my head under to look at the cab bolts…obviously they’d been taken out and put back with an impact multiple times, nice little ridge on the corners of the bolts, and im like ‘ohhh, ok, that makes a little more sense’

[matticus]

The guest you had was top notch on this video to. Very informative and serious, its almost like looking at that 6.0 was making him relive all the nightmare hellish years he delt with working on them.

[DatBoiOrly]

I'm so glad deboss does these videos goes through all these different diesels and tells us the common faults in them. Which is a hell of a lot easier than going though 20 different online forums with conflicting information just to see if it's worth putting the money into them many thanks Ritch for making these videos.

[MidWestRedBeard]

When you get the bill from this guys just know, he is worth the money and pay the man. A man's knowledge like this is priceless.

[JClinger]

Good to see DieselTechRon's old video's still pop up for references, absolute shame of his passing. RIP

[lbloodnolast]

I was gonna buy a 6.0 Excursion at 208K miles this weekend but that's pretty much a no go. This is hands down the most ridiculous teardown I've seen.

[edieseldad]

I bought a used 05 6.0 that was already bulletproof . Ran great for a few months, then it decided it didn’t want to start when room temperature to operating temp. (Started great when cold) Tested and changed multiple things. Finally figured out it was the main engine wire harness. Figure they ran the harness by the lifting ring on the driver’s side like an S and over time it broke a wire just enough to separate when warm but close the gap enough when cold and act like nothing was wrong. Wire harness for the win!

[skier]

Great video. Nailed most of the points.
Couple missing items:
-Updated fuel pressure (blue spring) Helps maintain fuel pressure under load. Injectors get damaged under 45psi.
Making sure FICM Main power voltage is above 45 volts. (47-48 volts optimal) Weak FICM can damage injectors.
-Oil coolers plug due to contamination in coolant. Restricts the flow in the EGR cooler causing it to crack. coolant enters the intake and raises cylinder pressures-floating the heads. EGR coolers typicall build coolant pressure fast and release fast. Pull EGR valve if its wet=cooler.
-Head gaskets require a long pull up a good hill with a trailer and get the boost up. pressure will slowly climb, but maintain presssure until cap releases at 15 psi.
-Oil coolers can crack. Either in winter due to poor antifreeze mix or seals let go in an overheat. oil pressure is higher than coolant, so it will pump engine oil into cooling system. It makes a mess. I have had that happen once to my personal truck coming across canada. We broke down at 9 am. Started wrenching at 10 am. Back on the road by 6:30 pm. 7 hour job with canadian tire ratchet, wrench, and pliers set. Brake cleaner, shop towels and a 40L plastic tote to drain the cooling system.
-Never use a dorman oil cooler. Most aftermarket coolers are good, seals are horrible. Buy a ford seal kit, mahle, or fel-pro.

I use fel pro for gaskets. Exotic Head studs is a great alternative to ARP at a fraction of the cost. If you are going to push 600 hp, I would go with ARP. but for stock injectors/turbo with a tune, they hold up just fine.

-The 05-10 cast iron HPOP's RARELY fail. the 03-04 aluminum pumps are known to get weak, ball bearing blows out the side and causes low oil pressure at idle, hot no starts, etc.
-Once you go into the oil system and update the STC, stand pipes and dummy plugs, I have never had a high pressure oil leak on that same truck. Aftermarket injectors are known to have bad seals. improperly installing the oil rail can snag an o ring and cause damage. That is installer error.
-Disassembling injectors to clean is not hard. However if you tighten the nut on the spool valve coil too tight, the engine will run great cold, but after 5 mins of running, you'll have multiple cylinder missfires. torque on injectors is critical.
-Camshaft and lifter failures due to improper valve geometry. There is an updated push rod. its the 6.4L one. about 0.100" shorter. If you are doing heads. At the bare minimum order new push rods. You can only change front 8 lifters. Rear 8 require engine or trans removal and rear cover removal.
-Aftermarket oil filters are the #1 source of oil contamination. They cause numerous IPR failiures. But they are easy to flush out and clean. I have only had one valve go bad from an engine overheat.
-Turbo chargers do commonly get "stuck" The unison ring rusts on the center cartridge. cleaning the carbon up and slightly enlarging the inside of the ring with a die grinder adds a bit of clearance to make them less likely to stick.
-Up pipes can crack and fail. Exhaust manifolds rust out. (same as 7.3L but much easier to replace)
-Never had a bottom end (rods, pistons, crank, bearings)
-Never had a transmission failure.We have 8 6.0's in the fleet in ontario. Most are landscaping trucks, water trucks or plow trucks. They are always hooked to a trailer. I've never driven a more comfortable pulling truck. The shifts are bang on, never hangs a gear. Never lugs a gear. And if it isn't running right, fix it.
-My personal truck has had bad head gaskets for 2.5 years now. (75 000 km ago). Never once has it left me stranded. It uses about a gallon of coolant every month. It has stock head bolts. I am curious to see what it looks like on tear down.

I've had to work on old second gen dodges as well. zip ties has it right. they're a glorified shipping crate. From the bad wiring, cracked dashes. horrible front ends, horrible steering. death wobble, horrible transmissions. Wheel bearings need to be removed to change brake rotors. tiny transmission coolers, horrible to access starters. bad brake line configurations. Fuel pick up rotting out. Fuel tank straps rotting out. Having to drop the engine mounts to access the rear valve cover. Pulling the head to pull the engine out of the frame, etc. By the time you fix ever one of those issues, you'll be doing it again because the front end is worn out....again. My lawn tractor has a better suspension than a second gen!

[roceye]

In the 6.0's defense- they do tolerate multiple teardowns and reassembles. Over and

[Michael-szhe]

Really like this guy. Quietly spoken, knowledgeable and said "no, I don't know so I'm not going to talk about my ass" about egr delete. Refreshing very nice to watch and listen to!

[TheRoostersGarage]

Seeing all the failure points, I'm astonished it got off the engineer's desk in the first place. But honestly, this looks like an engineer's dream - make it overly complicated and failure prone because it works in a lab.