HELP!!! 2003 6.0 Engine into a 2005 Truck with 6.0?? - Ford Powerstroke Diesel Forum
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Old 03-01-2013, 03:49 PM
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HELP!!! 2003 6.0 Engine into a 2005 Truck with 6.0??

Hi, I have a 2005 F350 6.0 with what I think are bad heads. Rather than spending the time to diagnose the problem, I got a great deal on a 2003 6.0 Diesel Motor. Once my mechanic removed my 6.0 out of the 2005, he realized that some sensors are in different locations and the heads and hpop are different. We are concerned that the motors are not interchangable. Is this possible? If so, how is it done? Please help!
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Old 03-01-2013, 07:58 PM
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icp sensor is located under turbo on the 03.
turbo
turbo pedestal
intake manifold
egr cooler
turbo up pipe
turbo y pipe
hpo pump
hpo branch tube
hpo feed lines
hpo rail
rocker boxes
ficm bracket
all different on 03

you can use all of it, if you have it.

how about we start here; how complete is the 03 engine?
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Old 03-02-2013, 01:03 AM
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kaya, thanks for the response. The 03 is complete from the oil pan to the turbo. With the exception of the power steering pump. I read on another forum that isaid I may have to modify the wiring harness also? And do I need the ficm and or the ecm reflashed?
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Old 03-02-2013, 08:27 AM
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your original pcm and ficm will be fine.
use everything from the 03 engine.
the icp sensor wiring will need to be modified to reach under the turbo. the easiest way would be to just cut the wires at the pcm, cut the icp connector off and run new wires to under the turbo with the icp connector spliced in. then just tape up the old cut wires.
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Old 03-02-2013, 09:04 AM
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Ok. So i just keep everything that is on the 03 and install it? Is the icp sensor the one that is located in the valve cover for the 05 motor?
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Old 03-02-2013, 10:11 AM
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yup. that's it. keep all the 03 stuff together. and yes, icp is on PS valve cover for 05.
transfer the 05 icp sensor as well. the late ones function the same as early, but are much less prone to leaking. and replacing that sensor with the engine out is a whole lot easier than when it's in there.

just a little info though for you on the differences of the engines;
the 03 HPO pump is much more prone to failure and operates a lower pressure than the 05. however, the 03 engines HPO system was less prone to HPO leaks. probably partly due to the lower pressure. also, the egr cooler on the 03 is a better design, with a much lower failure rate.

IMO, the 05 is a much better engine. so long as the HPO updates are done and egr is deleted.
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