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Symptoms · 6.0 Power Stroke (2003-2007)
6.0 Power Stroke (2003-2007): overheating or temperature creeping up
6 documented failures on this engine list this among their signs. They are ordered from the most widespread down. Each one shows the signs in its record's own words, how to tell it from the others, the usual fix and any recall or bulletin.
Not sure which engine you have, or want the recalls for your exact truck? Check your VIN: it names the engine and lists the campaigns for that model year. Whether a recall is still open on your VIN: nhtsa.gov/recalls.
verified
How widespread: Near-universal
37 NHTSA owner complaints match it, out of 336 checked
How it shows up
- overheating; low-coolant warning
Its other signs
- white, sweet-smelling smoke from the exhaust on acceleration or at idle
- coolant loss with no visible external leak
- bubbles or pressure build-up in the degas bottle
- rough running or misfire if coolant enters a cylinder
How to tell it apart
- chemical combustion-gas test on the coolant (block test)
- pressurise the cooling system and look for coolant entering the intake or exhaust
- borescope the intake / EGR passages
Usual fix
install an upgraded EGR cooler; ALWAYS replace or verify the oil cooler at the same time or it will fail again
Recalls and bulletins
TSB 09-15-6Voluntary Emission Recall 06E17TSB 05-4-17
Root cause, parts and sources →
verified
How widespread: Near-universal
25 NHTSA owner complaints match it, out of 336 checked
How it shows up
- overheating during towing or grades
Its other signs
- engine oil temperature (EOT) runs well hotter than engine coolant temperature (ECT) under load
- repeated EGR cooler failures
- coolant in the oil or oil in the coolant (internal cooler leak)
- reduced heater output
How to tell it apart
- 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)
- check for oil/coolant cross-contamination
- inspect coolant for the sludge that causes it
Usual fix
replace the oil cooler; thoroughly flush the cooling system at the same time
Recalls and bulletins
TSB 20228SB-20720TSB 04-18-6
Root cause, parts and sources →
aggregated
How widespread: Near-universal
How it shows up
- gradual overheating tendency under load
Its other signs
- brown, cloudy or rusty coolant
- sediment / sludge in the bottom of the degas bottle
- recurring oil cooler and EGR cooler failures on an otherwise sound engine
How to tell it apart
- inspect coolant colour and clarity; inspect the bottom of the degas bottle for sediment
- test coolant condition / pH / freeze point
- if the oil cooler or EGR cooler have failed, assume the coolant is contaminated
Usual fix
full cooling system flush, repeated until clean (a silicate-removing flush product is often used)
Recalls and bulletins
TSB 02-17-7
Root cause, parts and sources →
verified
How widespread: Very common
21 NHTSA owner complaints match it, out of 336 checked
How it shows up
- coolant overflow, overheating, sweet smell
- overheats and then stalls, and will not restart until cooled
Its other signs
- white smoke and coolant loss
- immediate pressurisation / bubbling in the degas bottle on start-up or under load
- misfire; coolant in a cylinder on borescope
How to tell it apart
- combustion leak (block) test confirming exhaust gas in the coolant
- cooling system pressure test
- running compression / cylinder leak-down
Usual fix
ARP head studs plus new head gaskets; machine-shop check of head and deck flatness; the gasket MUST match the dowel size (18mm: Ford 4C3Z-6051-EB, engines built before 2006-01-16; 20mm: Ford 6C3Z-6051-AA, engines built 2006-01-16 and newer - Ford catalog gasket application rows). Confirm dowel size by build date, measurement, or head casting number (18mm: 1843080C1/C2/C3; 20mm: 1870389C1); a step dowel (Ford 6C3Z-6B041-B) adapts 20mm heads to an 18mm block
Recalls and bulletins
TSB 08-23-8TSB 04-17-4
Root cause, parts and sources →
verified
How widespread: Common
How it shows up
- cap not holding pressure; false overheating or coolant-push symptoms that mimic head gasket / EGR cooler failure
Its other signs
- 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
How to tell it apart
- pressure-test the cap and the bottle
- inspect for hairline cracks and coolant staining
- rule this out before diagnosing head gasket or EGR cooler failure
Usual fix
replace the degas bottle and cap (inexpensive); do it during any other cooling-system work
Recalls and bulletins
TSB 05-26-23CSP 05B32TSB 05-17-13TSB 05-24-9
Root cause, parts and sources →
verified
How widespread: Common
How it shows up
- overheating with NO external leak (the classic sign of a spun / cracked plastic impeller: the pump turns but moves little coolant)
Its other signs
- coolant drip from the weep hole below the pump
- coolant loss; coolant staining on the front cover
- whine or growl from the front of the engine
- pieces of plastic impeller found in the coolant filter
How to tell it apart
- visual inspection at the weep hole and front cover
- check for water-pump shaft play
- if overheating with no external leak and the coolers/gaskets check out, suspect a spun or cracked impeller
Usual fix
replace the water pump (units with a metal impeller are preferred); replace the thermostat and degas bottle cap at the same time; refresh coolant
Root cause, parts and sources →
Other symptoms on the 6.0 Power Stroke (2003-2007)
Hard start, long crank or no-startStalls or dies while drivingLoss of power, limp mode or derateWhite smoke from the exhaustLosing coolantTicking, knocking, rattle or whineMisfire, rough idle, hesitation or surging
Everything on the 6.0 Power Stroke (2003-2007)Its recalls and bulletins