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2004 Ford Excursion

Reliability tier: verified - see /disclosure/

Engine: 6.0L (Power Stroke, 6.0L)

head dowel: 18mm. Late-2004 build ('2004.5') engines received the 2005-spec HPOP with the STC snap-to-connect fitting (fm-6-0-stc-fitting); a small early-2004 build window kept the round-style EGR cooler, the 90mm-impeller water pump and the 7-pin FICM - see part fitment notes.

Applicable failure modes (11)

• Cooling system degradation / no coolant filtration
• Degas bottle / coolant reservoir crack, or failed cap
• EGR cooler failure
• FICM (Fuel Injection Control Module) failure
• Marginal regulated fuel pressure (blue spring)
• Head gasket failure / cylinder head lift
• Fuel injector stiction / failure
• IPR (Injection Pressure Regulator) valve failure
• Engine oil cooler clogging / failure
• VGT turbocharger sticking
• Water pump failure

Applicable parts (24)

• Coolant Filter Element (replacement, SCA-free for HOAT)
• 6.0L Power Stroke Coolant Filtration Kit (spin-on)
• Ford Specification Gold HOAT Coolant (6.0L Power Stroke)
• 6.0L Power Stroke Degas Bottle (coolant reservoir)
• 6.0L Power Stroke Degas Bottle Pressure Cap
• 6.0L Power Stroke EGR Cooler, upgraded (Bullet Proof Diesel)
• 6.0L Power Stroke EGR Cooler Install Kit (gaskets, o-rings, hardware)
• 6.0L Power Stroke EGR Cooler, OEM-style replacement
• 6.0L Power Stroke EGR Valve
• 6.0L Power Stroke FICM (Fuel Injection Control Module), complete
• 6.0L Power Stroke FICM Power Supply (rebuild board, higher output)
• 6.0L Power Stroke Fuel Filter Set (HFCM lower + secondary/upper)
• 6.0L Power Stroke Fuel Pressure Regulator "Blue Spring" Upgrade Kit
• 6.0L Power Stroke Cylinder Head Bolt Kit (OEM torque-to-yield)
• 6.0L Power Stroke Head Gasket Set, 18mm dowel
• 6.0L Power Stroke Cylinder Head Stud Kit (ARP 2000)
• 6.0L Power Stroke ICP Sensor (Injection Control Pressure)
• 6.0L Power Stroke IPR Valve (Injection Pressure Regulator) with screen & o-rings
• 6.0L Power Stroke External / Relocated Oil Cooler Kit (Bullet Proof Diesel)
• 6.0L Power Stroke Oil Cooler Gasket / O-Ring Kit
• 6.0L Power Stroke Engine Oil Cooler (valley, oil-to-coolant)
• 6.0L Power Stroke Thermostat
• 6.0L Power Stroke VGT Turbocharger (reman / upgraded)
• 6.0L Power Stroke Water Pump

Platform recipes (5)

• The classic emissions-legal 6.0 bulletproof at stock power, using OEM-style coolers
• The full emissions-legal bulletproof: upgraded (round-tube) EGR cooler + external/relocated oil cooler that removes the OEM clog point entirely, ARP head studs with new gaskets matched to dowel size, complete cooling refresh, FICM upgrade, and full high-pressure-oil system refresh
• A modest, streetable power bump (tune + supporting mods) done the right way - on a bulletproofed, studded bottom-of-the-cascade truck
• Preventive baseline for a stock, healthy 6.0 with no current failures
• For a stock-power 6.0 used to tow, with no full bulletproof budget yet