difference between front covers - Ford Powerstroke Diesel Forum
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Old 07-01-2014, 08:03 PM
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difference between front covers

So, I broke a hole in my front cover, while getting the fan off to change the water pump. Truck is an early 04.

From what I can find, there are 3 different covers, 03-early 04.5, late 04.5 only, and 05-07. I am trying to figure out what the differences are.

Is the difference between early and late just the water pump and the difference between late and 05+ the radiator hose inlet angle/size.

How interchangeable are they? If I use the larger water pump is the late 04.5 a direct swap? Can I use the 05-07 cover by only swapping to the large water pump and a different radiator hose or will my steering box interfere?

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Old 07-02-2014, 01:57 AM
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If IIRC the early 04 and 03 were the same engine the late 04 only difference was the depth of the impeller. Same diameter and bolt pattern you had to watch that you didn't get an 03 and install cause it would fit but the flow would be wrong.

The 05 you allready covered the differences your self. That PS pump is a major pain.
I would definately clean the CAC if you were getting serious blow by for a while. Same with the early boots, the oil tended to make them softer and may never fit right again.
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Old 07-02-2014, 10:51 AM
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6.0L "Geniuses" (engineers) @ Ford continue to amaze

Did you read that thread.

I found with the power steering pump it was easier to pull the big hose off of it, undo the front cover and tilt it so you can reach the back bolts. One bolt is under the other pressure hose from the pump and is the hardest to get. I think in the future it would be easier to remove that hose from under the truck then remove the four retaining bolts.

I am not a ford tech though so they may have a good procedure for removing that guy.
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