2003-2007 Ford 6.0L Powerstroke Engine Components

Engine components on the 2003-2007 Ford 6.0L Powerstroke

The parts in this section come from all over the engine. In the valley, the oil cooler sits up front and the high-pressure oil pump (HPOP) at the rear, both under the intake and turbo. On the driver-side valve cover, the FICM boosts battery voltage to 48 volts to fire the injector spool valves. The glow plug control module and harnesses power the glow plugs, and the EOT and ECT sensors report oil and coolant temperature to the PCM. In the block, a gear-driven cam works hydraulic roller lifters, pushrods and four valves per cylinder.

What fails and why

The oil cooler is the big one. It is a stacked-plate exchanger with coolant passages under 0.5 mm in places, and casting sand, rust and silicate from old coolant plug it. Originals commonly restrict between 100,000 and 175,000 miles, sooner on trucks that tow or run old coolant. A restricted cooler starves the EGR cooler of coolant, and EGR cooler failure usually follows. The tell is the gap between oil and coolant temperature: on a warmed-up truck at steady highway load, under 10 F is healthy and 15 F or more means the cooler is restricted.

Glow plug parts trip people up at service time. The 2004 engine got a new piston bowl and 1.2 mm shorter glow plugs, and a longer 2003-style plug in a 2004 or later engine risks piston-to-glow-plug contact. The harnesses are split by year too, with separate listings for 2003-2004 and 2004.5-2007 engines. On the high-pressure oil side, the 2003-2004 swash-plate HPOP and the 2005-2007 V-4 pump are not interchangeable without the matching branch tube and fittings.

Stock replacement vs. upgrade

Most parts here are direct replacements. Alliant Power sensors and the glow plug control module, Dorman dipsticks and the relay module, and the electric vacuum pumps from both go back in where the old part came out. The oil cooler is a real choice: Dorman, Mishimoto and PPE offer replacement coolers, and PPE also has a heavy-duty oil cooler and gasket kit. Valvetrain parts from XDP, such as HD high-boost valve springs, billet rocker arm valve bridges and street performance pushrods, are the step up for trucks running more boost than stock. Head studs and inner row head bolts replace the factory torque-to-yield bolts, which cannot be reused; studs are highly recommended before you add power.

What we carry

• Oil cooler: replacement coolers and kits from Dorman, Mishimoto and Pacific Performance Engineering, plus PPE oil cooler gasket kits with and without the screen.
• Glow plug system: Dorman and Mishimoto glow plug harnesses, the Dorman glow plug relay module and the Alliant Power glow plug control module (GPCM).
• High-pressure oil: Alliant Power remanufactured HPOPs for 2003-2004 and 2004.5-2007 engines, Mishimoto rail ball tubes, and the PPE ball tube and install tool kit.
• Valvetrain and bottom end: XDP valve springs, rocker arm valve bridges, pushrods, a stock-replacement harmonic balancer and balancer bolt set, XDP X220 head studs and inner row head bolts, pistons, and Mahle cylinder head dowel pins.
• Sensors and small parts: Alliant Power oil pressure and EOT/ECT sensors, Dorman and Alliant Power electric vacuum pumps, Dorman dipsticks, rear main seal cover and crankcase breather hose, Mahle crankcase breather gaskets and a Mishimoto oil filler cap.
• Fan: the Dorman cooling fan clutch, clutch fan blade and upper radiator support air deflector.
• Also in this section: parts from Fleece Performance Engineering, Gator Fasteners, BD Diesel and No Limit Fabrication.

Fitment notes

Before you order, know three things about your engine: whether it was built before or after 9/22/2003, whether it has the 2003-2004 or the 2005-2007 HPOP, and whether it takes the early or late glow plug. Many year ranges in our titles follow those splits, including the 2004.5 break, so read them closely. Early 2003 Super Dutys were still 7.3L trucks, and a 2005 Excursion can carry a 2004-type engine. Verify by VIN, or call the shop with it. All our Ford diesel parts are on the Powerstroke page.

Frequently asked questions

What does the EOT/ECT delta say about my oil cooler?

It is the gap between engine oil temperature and engine coolant temperature on a warmed-up truck at 65 to 70 mph. Under 10 F is healthy, 10 to 15 F is a warning, over 15 F means restricted and over 20 F means replacement is overdue. EOT over 240 F means replace it now; the PCM defuels around 255 F.

Can I put 2003 glow plugs in a 2005 6.0L?

No. From the 2004 engine on, glow plugs are 1.2 mm shorter along with a new piston bowl, and a longer 2003-style plug in a later engine risks hitting the piston. The harnesses are split by year as well, so match the listing to your engine build.

Which remanufactured HPOP fits my truck?

Alliant Power lists remanufactured pumps for 2003-2004 engines and for 2004.5-2007. Ford built two designs: an aluminum swash-plate pump on 2003-2004 engines and a cast-iron V-4 piston pump with a Snap-To-Connect fitting on 2005-2007. They do not interchange across that split without the matching branch tube and fittings, so identify the pump on your engine first.

What should a complete oil cooler job include?

Ford's own service kit, 3C3Z-6A642-CA, is a good checklist: the heat exchanger, the pump inlet strainer, nine O-rings, three gaskets and one seal. The cooler cover is reusable. If the EGR cooler has failed, do the oil cooler at the same time, or the new EGR cooler can fail again within 30,000 to 50,000 miles.

Not sure what fits? Call the shop at the number in the header, or use the fitment checker on any product page. We install everything we sell.