6.0 gone bad, the rebuild is this over kill? - Ford Powerstroke Diesel Forum
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Old 01-05-2012, 05:29 PM
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6.0 gone bad, the rebuild is this over kill?

I bought a 2004 6.0 psd last year with 130k on it. After owning it for a month I had 3 injectors fail as well as the oil cooler. I replaced the injectors, cooler, and did a egr delete. Now at 200k it has a blown head gasket and another failed oil cooler and one hell of a cold start issue. I talked it over with the wife and said enough is enough. I decided to pull the motor and have it completly rebuilt. The goal is reliabliity and a good balance of MPG and HP or just a lot of HP I really havent decied yet.
.. here is a list of upgrades that i am doing.

all new internals,
head and block pressure checked and resurfaced
head studs
bored .020 over

now for the fun stuff.
bullet proof diesel oil remote oil cooler
new HPOP
crank case vent
bypass oil filter (there sill be a total of 2 oild filters)
bypass coolant filter,
coolant return kit
strictly diesel regulated fuel system upgrade
elite diesel stage 2 185cc injectors
swamps 58v ficm
gauges (eot, ect, boost, pry, fuel pressure, volt gage, trans temp)
changing from 3.73 gears to 4.88 ( i have 37.5" tires)
sct tuner
custom intake manifold ( I modified mine for egr delete)
cfm intake
sct tuner
new turbo not sure which one yet

i will post pictures and as much info as possible, if i am missing something just let me know

Last edited by redarrow325; 01-05-2012 at 05:31 PM. Reason: spelling
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Old 01-05-2012, 05:33 PM
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Looks great to me but if you pull any kinda weight the 185cc sticks would be a little much.
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Old 01-05-2012, 05:45 PM
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Was the system flushed before the second oil cooler if not that may be one of the reason the cooler plugged from the casting sand and silicate drop out from the Ford Gold. I would look at the Radiator close to see what it looks like then when you fill go back with an ELC CAT EC-1 Rated coolant.
2 stroker
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Old 01-05-2012, 05:49 PM
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how did you drive 70,000 miles in a year? build looks fun Goodluck
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Old 01-05-2012, 06:35 PM
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Since it's not too expensive, I'd toss in a new radiator, who knows what may be lurking in there after 200k? Cheap insurance for an expensive rebuild. When they bore your block, make sure they use a deck/torque plate when doing the final honing of the block.

You may also want to check out this thread, very informative about a 6.0 build: How to Machine the 6.0
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Old 01-05-2012, 07:50 PM
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Thanks for the info, I will defiantly check with the shop to see if they will use a torque plate.
I live in NC and I drove to NY and Indiana several times (1400 miles round trip) and 4 trips to Arizona and California each about 2500 miles one way, not to mention the running around town and the 500 miles a week to and from work.
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Old 01-05-2012, 07:56 PM
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I would wait until you tear it open to see if you even have to bore it out. You might not have to.
If you do have to completely disassemble it, it might be cheaper to buy a new short block and go from there.
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Old 01-05-2012, 08:04 PM
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ok for one holy crap 70k in one year! my butt hurts just thinking about driving that much! looks to me like you got everything covered
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Old 01-05-2012, 08:24 PM
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You can also buy a rebuilt engine, bored, studded and everything else for $7k. I forget the website but I'm sure somebody will chime in with the website name.
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Old 01-05-2012, 09:07 PM
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Question Rebuilding MY 6.0 Power Stroke

Well, I've been reading about everyone's issues with this engine and it is now my turn to spend some big $$$. I have been much luckier than most in that I haven't had many issues with it until I hit 204,000 miles, 2003 vintage.

I use it for a hunting vehicle and occasional towing. I blew my head gasket on my last trip in the WY mountains. There are also 2 bad injectors.

My plans are as follows:

- Replace 8 injectors - any strong opinions on which to buy, I am inclined to buy stock injectors

- Edge Tuner and Monitor - my primary interest is economy tune, max MPG

- In anticipation of this day I purchased the Head Bolts in the blue box, new head gaskets, manifold gaskets, Sinclar EGR Delete.

- Advice appreciated, thinking I should replace the turbo with the performance Garrett, glow plugs, vacuum pump, High Pressure Oil pump, Amsoil Bypass Oil Filter, Sinclair Bypass coolant filter system.

How did your project turn out?
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