Engine swap: 2004 - 2006 - Ford Powerstroke Diesel Forum
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post #1 of 12 Old 04-11-2012, 05:59 AM Thread Starter
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Engine swap: 2004 - 2006

I am thinking of pulling my tired 2004 6.0 Powerstroke and putting in a 2006 6.0 Powerstroke. I know that the 2003 had a lot of diffences I was just checking to see if the 2004 to 2006 engine swap would be a doable swap? If not would the heads work from a 2005 or 2006 on my 2004 as a backup plan?

Thanks for your time,

Joel


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post #2 of 12 Old 04-11-2012, 06:04 AM
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If the engine is complete, you should be good. The heads would work but you would need a dowel insert since the 06 heads would have a 20mm dowel size and the 04 heads would have an 18mm dowel size. (PS. You would NOT be able to put your 04 heads on the 06 block.)

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post #3 of 12 Old 04-11-2012, 06:08 AM Thread Starter
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Quote:
Originally Posted by Evil Eye View Post
If the engine is complete, you should be good. The heads would work but you would need a dowel insert since the 06 heads would have a 20mm dowel size and the 04 heads would have an 18mm dowel size. (PS. You would NOT be able to put your 04 heads on the 06 block.)
Thank you about the note about the dowel sizes. What about the wiring. All sensors in the same place? Would I be able to use the 2004 ecu with the 2006 engine?

Joel

04 F250 Lariat CC SB 4x4,
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post #4 of 12 Old 04-11-2012, 06:27 AM
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Quote:
Originally Posted by Intrnlstorm View Post
Thank you about the note about the dowel sizes. What about the wiring. All sensors in the same place? Would I be able to use the 2004 ecu with the 2006 engine?

Joel
Double check on your 04 that your ICP is in the passenger side valve cover. If it is, your sensors are in the same place. If it isn't, you have an 03 engine and you might need a new engine harness.

Shawn Carlson
EvilEye@powerstroke.org

Proud Navy Vet
2005 F250, CCSB, 6.0 PSD, FX4 (The Sweet Unit is white)
2008 F350, CCLB, 6.4 PSD (Brad-the wife's truck is black)




Engine Mods:
Fluidampr
CCV Reroute (Reinstated)
4" MBRP Exhaust
MTW Stage 1 Turbo
Bulletproof 53V FICM
BulletProof EGR Cooler
BulletProof Water Pump
Riff Raff Intercooler Boots
Gogo Diesel Direct Drive Solenoid
BulletProof All-Aluminum Radiator
BulletProof All-Aluminum Intercooler
BulletProof Oil Cooler System w/ Bypass Filter
SCT w/ Custom Tunes (TSD, DJ's, Innovative, Gearhead, QuickTricks)

Exterior Mods:
Bilstein 5100 Shocks
Icon Adjustable Trac Bar
Firestone RideRite Air Bags
BDS Dual Steering Stabilizer
Aluminum Finned Differential Cover
Reese 16k Manual Slider 5th Wheel Hitch
Icon 2.5" Leveling Kit w/ F-350 rear blocks
20" BMF Novakanes wrapped in 33" Nitto Terra Grapplers
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post #5 of 12 Old 04-11-2012, 07:12 AM Thread Starter
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Quote:
Originally Posted by Evil Eye View Post
Double check on your 04 that your ICP is in the passenger side valve cover. If it is, your sensors are in the same place. If it isn't, you have an 03 engine and you might need a new engine harness.
My ICP is on the passenger cover? Where is it on the 2003? How about my ecu from the2004? Or should I buy the 2006 ecu from the engine for another $200?

Joel

04 F250 Lariat CC SB 4x4,
Insight with EGR Sensor
ARP Studs with OEM head gaskets
Blue spring mod
6.4 Banjo Bolts
High Idle Mod
EGR deleted
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post #6 of 12 Old 04-11-2012, 07:18 AM
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ICP on a 2003 truck is by the turbo...

Yours is good to swap to that 06...

IIRC all you need is all of the matching computers..(I assume you have ALL of the computers from your 04)


The computers don't care what year the block is... they just need to talk to each other

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post #7 of 12 Old 04-11-2012, 08:28 AM Thread Starter
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Quote:
Originally Posted by Six0~Stroker View Post
ICP on a 2003 truck is by the turbo...

Yours is good to swap to that 06...

IIRC all you need is all of the matching computers..(I assume you have ALL of the computers from your 04)


The computers don't care what year the block is... they just need to talk to each other
The 2004 is all together and running, just need new head gaskets. The 2006 is also in a running truck but he is pulling it to go to a cummins and offered it to me for a pretty good price I think. I was figuring to do the head studs on the 2006 and then do an engine swap to limit downtime. So as you guys say, all I need is the engine and I'm good to go?

What about the hpop or ipr? I thought they were worst in the 2006 trucks compared to the 2004 truck but can't remember.

Joel

04 F250 Lariat CC SB 4x4,
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ARP Studs with OEM head gaskets
Blue spring mod
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High Idle Mod
EGR deleted
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post #8 of 12 Old 04-11-2012, 08:32 AM
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03 HPOP is the bad one IIRC...

IPR is teh same...What you need for the 06 is the STC fitting on the HPOP


Bottom right corner of pic.



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post #9 of 12 Old 04-11-2012, 08:34 AM
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Make sure to run OEM Head Gaskets and follow the ARP torque down instructions provided WITH your kit...They were changed as some point

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post #10 of 12 Old 04-11-2012, 09:16 AM
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Ok stupid question here. Why the change back to OEM head gaskets? When I had mine changed out about a year ago all the talk here was about using Black Onyx. I have gone from feeling fairly secure to not so after reading recent post's.
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