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Recalls and bulletins

6.0 Power Stroke (2003-2007) recalls and service bulletins

3 NHTSA safety recalls name this engine, and we document 33 manufacturer bulletins, programs or coverages tied to its known failures. Each entry shows the campaign number, the model years, what was wrong and what the fix is.

6.0 Power Stroke (2003-2007): failure modes and parts Safety recalls 3 Federal investigations 1 Bulletins and programs 33
Check a specific truck: enter its VIN at nhtsa.gov/recalls for open safety recalls, and ask a dealer about emissions recalls and coverage programs, which NHTSA's lookup does not always show. Recall repairs are free on an eligible VIN.

Safety recalls (NHTSA)

Newest first. NHTSA's own summary and remedy text, for the models and years this engine was sold in.

09V-399 Safety recall October 13, 2009 · 2003

FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.

Risk and remedy

Risk: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.

Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.

Models in our scope: EXCURSION, F-250 SD, F-350 SD, F-450 SD, F-550 SD

05V-270 Safety recall June 10, 2005 · 2004-2005

CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.

Risk and remedy

Risk: SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.

Remedy: DEALERS WILL UPGRADE THE FUEL INJECTION CONTROL MODULE (FICM) WIRE HARNESS OR REPLACED, AND/OR HAVE A NEW INJECTION CONTROL PRESSURE (ICP)) SENSOR CONNECTOR INSTALLED FREE OF CHARGE. THE RECALL BEGAN ON JULY 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

Models in our scope: E-350, E-450, EXCURSION, F-250 SD, F-350 SD, F-450 SD, F-550 SD

Failure mode: FICM (Fuel Injection Control Module) failure

04V-327 Safety recall July 7, 2004 · 2003

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH 6.0L DIESEL ENGINES, THE ENGINE GROUND STUD THAT ATTACHES THE NEGATIVE BATTERY TERMINAL EYELET TO THE ENGINE BLOCK MAY BE LOOSE.

Risk and remedy

Risk: IF THE GROUND WIRE IS LOOSE, ELECTRICAL CURRENT MAY FLOW TO THE RADIO SUPPRESSION STRAP CAUSING IT TO HEAT AND POTENTIALLY MELT OR IGNITE ADJACENT COMPONENTS WHICH COULD RESULT IN A FIRE.

Remedy: DEALERS WILL REPLACE THE ENGINE GROUND STUD AND THE RADIO SUPPRESSION STRAP AND ADJACENT COMPONENTS WILL BE INSPECTED FOR DAMAGE AND REPLACED, IF NECESSARY. THE RECALL BEGAN ON JULY 23, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.

Models in our scope: EXCURSION, F-250, F-350, F-450 SD, F-550 SD

Federal defect investigations (NHTSA)

Investigations NHTSA's Office of Defects Investigation opened into trucks with this engine, newest first. An open investigation is not a recall: NHTSA is still deciding whether a safety defect exists. Subject and summary are NHTSA's.

EA05003 Engineering analysis Opened February 15, 2005 · closed November 2, 2005 · 2003-2004

Engine stalling. Led to recall 05V-270.

NHTSA's summary

IN A JUNE 7, 2005 LETTER, FORD NOTIFIED ODI THAT IT WOULD BE CONDUCTING A SAFETY RECALL OF APPROXIMATELY 180,000 FORD F-SUPER DUTY, EXCURSION AND E-SERIES VEHICLES EQUIPPED WITH 6.0L DIESEL ENGINES TO CORRECT TWO WIRING RELATED CONDITIONS THAT COULD RESULT IN ENGINE STALL (NHTSA RECALL NO. 05V-270, FORD NO. 05S34).THE AFFECTED VEHICLES WERE BUILT BETWEEN SEPTEMBER 29, 2003 AND MAY 31, 2004.ACCORDING TO FORD, VEHICLES WITH THE CONDITIONS MAY STALL WITHOUT WARNING AND MAY OR MAY NOT RESTART.FORD WILL INSTRUCT OWNERS OF VEHICLES INCLUDED IN THE RECALL TO TAKE THEIR VEHICLES TO A DEALER TO HAVE THE FUEL INJECTOR CONTROL MODULE WIRE HARNESS UPGRADED OR REPLACED AND OR HAVE A NEW INJECTION CONTROL PRESSURE SENSOR CONNECTOR INSTALLED.DURING A MAY 2005 PRESENTATION TO ODI, FORD IDENTIFIED A NUMBER OF POTENTIAL FAILURE MECHANISMS THAT COULD AFFECT ENGINE PERFORMANCE IN VARIOUS SEGMENTS OF THE SUBJECT VEHICLE POPULATION, INCLUDING THE WIRING CONDITIONS ADDRESSED BY 05V-270.THE WIRING CONDITIONS, WHICH BOTH AFFECT ENGINE FUELING, WERE THE MOST LIKELY CONDITIONS TO RESULT IN ENGINE STALL.THE RECALLED VEHICLES COMPRISE APPROXIMATELY 43% OF THE SUBJECT VEHICLE POPULATION AND ACCOUNT FOR 75 OF THE 113 ODI REPORTS THAT HAVE A VALID VIN (66%).THE VOQ COMPLAINT RATE FOR THE RECALL POPULATION IS 45/100K WHILE THE RATE FOR VEHICLES OUTSIDE THE RECALL POPULATION IS 17/100K AND THEIR TREND (BY DATE OF RECEIPT) IS DECLINING.BASED ON THE ANALYSIS, ODI BELIEVES FORD?S ACTIONS ARE SUFFICIENT TO ADDRESS THE CURRENT SAFETY RISKS AND THE INVESTIGATION IS THUS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY RELATED DEFECT DOES NOT EXIST.FURTHER ACTION WILL BE TAKEN IF WARRANTED BY FUTURE CIRCUMSTANCES.

Models in our scope: Ford EXCURSION, Ford F SUPER DUTY, Ford F-250 SD, Ford F-350 SD, Ford F-450 SD, Ford F-550 SD

Bulletins, programs and coverage

Manufacturer service bulletins, special coverages, programs and emissions recalls that bear on this engine's documented failures. Identifier, date and scope only; bulletin text is the manufacturer's.

TSB 10-12-6 Service bulletin 2010-06 · 2003-2010

RUNS ROUGH, LACKS POWER, HARD START, NO START. SOME VEHICLES AND TRUCKS EQUIPPED WITH 6.0L ENGINE MAY EXHIBIT A RUNS ROUGH, LACKS POWER, HARD [START] ...

Failure mode: Fuel injector stiction / failure

TSB 09-15-6 Service bulletin 2009-12 · 2003-2004

SOME VEHICLES EQUIPPED WITH THE 6.0L ENGINE MAY EXPERIENCE A P006A, P132[B], P0401 OR P0402 DIAGNOSTIC TROUBLE CODE (DTC) WITH A LACK OF POWER CONDITION.

Failure mode: EGR cooler failure

TSB 08-26-3 Service bulletin 2009-06 · 2003-2009

SOME VEHICLES WITH DIESEL ENGINES MAY EXPERIENCE NO STARTS, HARD STARTS OR ROUGH RUNNING WHEN COLD AND MAY BE ACCOMPANIED WITH DIAGNOSTIC TROUBL[E CODES] ...

Failure mode: Fuel injector stiction / failure

TSB 20228 Service bulletin 2008-04 · 2002-2008

1999-2008 7.3L/6.0L/6.4L/4.5L DIESEL F-SUPER DUTY - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP.

Failure mode: Engine oil cooler clogging / failure

SB-20720 Service bulletin 2008-03 · 2008-2009

FORD SD TRUCKS; THIS NON MIL DTC WILL BE STORED IN THE POWERTRAIN CONTROL MODULE (PCM) WHEN THE ENGINE OIL TEMPERATURE (EOT), ENGINE COOLANT TEMPERATU[RE] ...

Failure mode: Engine oil cooler clogging / failure

Voluntary Emission Recall 06E17 Emissions recall 2006-04 · 2003-2004

VOLUNTARY EMISSION RECALL 06E17 SUPPLEMENT #1: CONTROL MODULE RECALIBRATION. CORROSION MAY EXIST AT THE ELECTRODE SURFACE ON THE EXHAUST PRESSURE [SENSOR] ...

Failure mode: EGR cooler failure

TSB 05-4-17 Service bulletin 2005-03 · 2002-2005

INTERMITTENT ROUGH IDLE - NON-COMMANDED EGR (EXHAUST GAS RECIRCULATION VALVE) FLOW.

Failure mode: EGR cooler failure

Method: safety recalls come from NHTSA's recall database, pulled for every make, model and year this engine covers; a recall is listed when its NHTSA text names this engine (fuel type, displacement or engine family) and left out when it names no engine. Defect investigations come from NHTSA's investigations file by the same rule, or when the investigation cites a recall listed here. Bulletins and programs come from the failure-mode records on this site, each with its source. Pulled 2026-10-26. How we tier and source facts.