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Symptoms · 6.0 Power Stroke (2003-2007)
6.0 Power Stroke (2003-2007): white smoke from the exhaust
3 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
- white, sweet-smelling smoke from the exhaust on acceleration or at idle
Its other signs
- coolant loss with no visible external leak
- bubbles or pressure build-up in the degas bottle
- overheating; low-coolant warning
- 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: Very common
21 NHTSA owner complaints match it, out of 336 checked
How it shows up
- white smoke and coolant loss
Its other signs
- immediate pressurisation / bubbling in the degas bottle on start-up or under load
- coolant overflow, overheating, sweet smell
- overheats and then stalls, and will not restart until cooled
- 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
27 NHTSA owner complaints match it, out of 336 checked
How it shows up
- white smoke on cold start
Its other signs
- rough cold idle or misfire that clears as the engine warms up
- hard start, low power
- low cylinder contribution on a scan-tool balance / buzz test
How to tell it apart
- cylinder contribution / buzz test, cold and warm
- note whether the miss clears with temperature (points to stiction)
- oil analysis; check for high-pressure oil aeration
Usual fix
stiction-reducing oil additive as a stopgap only
Recalls and bulletins
TSB 10-12-6TSB 08-26-3TSB 08-23-8TSB 03-20-10TSB 03-... (OASIS 16607 / 16670 / 16791)
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 derateLosing coolantOverheating or temperature creeping upTicking, knocking, rattle or whineMisfire, rough idle, hesitation or surging
Everything on the 6.0 Power Stroke (2003-2007)Its recalls and bulletins