Used 6.0 Power Stroke (2003-2007): what to check before you buy

1Before you go

Run the VIN and ask for the paperwork on the campaigns below: a done recall or program is a solved problem, an open one is a free repair the seller has not had done.

• Run the VIN

  It confirms the engine and lists the campaigns for that model year. Whether a recall is still open on this VIN: nhtsa.gov/recalls.

• Safety recalls on this engine
  • 09V-399 · 2003 · Vehicle speed control
  • 05V-270 · 2004-2005 · Electrical system
  • 04V-327 · 2003 · Electrical system
• Programs, extended coverages and emissions recalls
  • Voluntary Emission Recall 06E17 · Emissions recall · 2003-2004
  • CSP 05B32 · Program · 2005
  • Emissions Recall 03E03 · Emissions recall · 2003-2004
  • CSP 03B05 · Program · 2003

  Plus 29 service bulletins on the recalls page.

2Cold start and idle

Ask the seller not to start or warm the engine before you arrive. Most of these only show on a cold engine; then let it idle and listen.

• EGR cooler failure
  • white, sweet-smelling smoke from the exhaust on acceleration or at idle
• FICM (Fuel Injection Control Module) failure
  • hard start when cold; extended crank
  • dead cylinder or rough miss, worst when cold, improving as the engine warms
• Head gasket failure / cylinder head lift
  • white smoke and coolant loss
  • overheats and then stalls, and will not restart until cooled
• Fuel injector stiction / failure
  • rough cold idle or misfire that clears as the engine warms up
  • white smoke on cold start
  • hard start, low power
• IPR (Injection Pressure Regulator) valve failure
  • hard start, no-start, or stall at idle
  • surge / hunt at idle

3Scan for codes

A basic OBD-II reader shows stored and pending codes; on a diesel ask a shop for a full scan if you can. These are the codes our records tie to known failures on this engine.

What a code means on each engine: trouble codes by engine.

4Hood up and underneath

Engine off, in daylight, with a flashlight.

• EGR cooler failure
  • coolant loss with no visible external leak
  • overheating; low-coolant warning

  To confirm: chemical combustion-gas test on the coolant (block test)

• Engine oil cooler clogging / failure
  • coolant in the oil or oil in the coolant (internal cooler leak)

  To confirm: with a scan tool, compare EOT and ECT at steady highway load: a delta above roughly 15 F indicates restriction (SME to confirm exact threshold)

• Head gasket failure / cylinder head lift
  • coolant overflow, overheating, sweet smell
  • misfire; coolant in a cylinder on borescope

  To confirm: combustion leak (block) test confirming exhaust gas in the coolant

• Degas bottle / coolant reservoir crack, or failed cap
  • coolant seepage and staining around the reservoir at the top rear of the engine
  • slow, unexplained coolant loss; coolant smell
  • coolant overflow from the degas bottle

  To confirm: pressure-test the cap and the bottle

• Water pump failure
  • coolant drip from the weep hole below the pump
  • coolant loss; coolant staining on the front cover

  To confirm: visual inspection at the weep hole and front cover

5Test drive

At least 20 minutes, including a highway run and a hill or a load if you can.

• EGR cooler failure
  • rough running or misfire if coolant enters a cylinder
• Engine oil cooler clogging / failure
  • overheating during towing or grades
• Cooling system degradation / no coolant filtration
  • gradual overheating tendency under load
• Marginal regulated fuel pressure (blue spring)
  • power loss or hesitation under load, especially with a tune or upgraded injectors
• FICM (Fuel Injection Control Module) failure
  • buck / surge at light load
  • sudden stall while driving with total loss of throttle response; may or may not restart
  • buzzing / fizzle noise from the FICM under the hood
• VGT turbocharger sticking
  • low power / sluggish spool-up
  • surging or hunting boost
  • overboost or underboost fault codes (P0299, P2262, P2263); occasional limp mode
  • loud exhaust 'bark' / sneeze; weak exhaust brake
• Degas bottle / coolant reservoir crack, or failed cap
  • cap not holding pressure; false overheating or coolant-push symptoms that mimic head gasket / EGR cooler failure
• Water pump failure
  • whine or growl from the front of the engine
  • overheating with NO external leak (the classic sign of a spun / cracked plastic impeller: the pump turns but moves little coolant)

6After the drive

Hot engine, parked: the dipstick and the coolant reservoir tell you what the drive did. Then shut it off and restart it hot: some failures only show on a hot restart.

• EGR cooler failure
  • bubbles or pressure build-up in the degas bottle

  To confirm: chemical combustion-gas test on the coolant (block test)

• Head gasket failure / cylinder head lift
  • immediate pressurisation / bubbling in the degas bottle on start-up or under load

  To confirm: combustion leak (block) test confirming exhaust gas in the coolant

• STC fitting (high-pressure oil rail) failure2005-2010
  • long crank / hard start when hot; may start fine cold
  • no-start when hot
  • rough run immediately after a hot restart, then smooths out

  To confirm: monitor ICP on a hot restart: slow to build, or won't reach the roughly 500 psi crank threshold

What it costs if you find it

Parts budgets from our repair recipes for this engine: Dave's Auto Center's prices where Dave's lists the part, approximate OEM and maker catalog prices (rounded) for the rest; labor not included. A campaign listed next to a failure may make the repair free on a covered truck: check it by VIN.