2003-2007 Ford 6.0L Powerstroke Valve Covers

Valve covers on the 2003-2007 Ford 6.0L Powerstroke

The 6.0L runs a gear-driven cam in the block with hydraulic roller lifters and four valves per cylinder, so the valve covers seal the top of an overhead-valve layout. Kits here cover both the valve cover and the rocker box, also called the rocker carrier, which has its own gasket set. The driver-side cover does extra duty. The FICM, which boosts battery voltage to 48 volts to fire the injectors, mounts on it under the degas bottle. For 2004 Ford moved the crankcase breather to an external mount on the driver valve cover, and the compressor inlet hose bracket doubles as the FICM retainer. That breather routes crankcase vapor to the turbo compressor inlet as part of the closed crankcase ventilation system.

What to watch for

If your valve covers are coming off, two electrical parts are worth a look. The ICP sensor and its pigtail connector are both known failure points, from oil intrusion and damaged wires; inspect the pigtail and replace it along with the sensor. On 2003-2004 engines the ICP sensor is on the HPOP cover under the turbo, and from 2004.5-2005 on it moved to the passenger-side rail and valve cover area. The other is the FICM on the driver-side cover. FICM failures on the 6.0L are driven by weak batteries, and Ford's minimum output is 45 volts.

If you are here for more than valve cover gaskets, the head gasket sets matter. Head gasket failure on the 6.0L comes from stretched torque-to-yield head bolts, and the signs are coolant pushed out of the degas bottle or bubbling in it under load, a heater blowing cold once hot, overheating while towing, and white smoke.

Stock replacement vs. upgrade

Gaskets are a replace-with-new job, so the choice is how far into the engine you are going. For the top end alone, the valve cover gasket sets, the Dorman rocker box and valve cover gasket kit and the Mahle rocker carrier gasket set are the parts to look at. If the heads are coming off, look at the Mahle head gasket sets and engine gasket sets, some of which are listed by dowel size. That is also the time to replace the factory torque-to-yield head bolts with studs, since TTY bolts cannot be reused and studs are the standard fix.

What we carry

Mahle supplies most of this section: valve cover gasket sets, a rocker carrier gasket set, cylinder head gasket sets in 18 mm and 20 mm versions, an 18 mm engine gasket set, and an engine gasket set without head gaskets. Dorman offers a rocker box and valve cover gasket kit, Alliant Power a valve cover gasket kit, and Mishimoto an oil filler cap that fits the 7.3L, 6.0L and 6.4L Powerstroke.

Fitment notes

Head gasket sets and the 18 mm engine gasket set are listed by dowel size and year range, and both need to match your engine. The valve cover, rocker box and rocker carrier gaskets here are listed for the full 2003-2007 run. Early 2003 Super Dutys were still built with the 7.3L, and a 2005 Excursion can carry a 2004-type engine, so confirm by VIN or engine build date before you order. All our Ford diesel parts are on the Powerstroke page.

Frequently asked questions

Where is the FICM on a 6.0L Powerstroke?

On the driver-side valve cover, under the degas bottle. It boosts battery voltage to 48 volts to fire the injector spool valves, and 45 volts is Ford's minimum. On 2004 and later engines the compressor inlet hose bracket also serves as the FICM retainer.

Should I replace the ICP pigtail with the sensor?

Yes. Both the sensor and its pigtail connector are known failure points, from oil intrusion and damaged wires, so a new sensor on an old pigtail can leave the problem in place. Inspect the pigtail and replace it with the sensor.

Do I need a head gasket set or just valve cover gaskets?

It depends on the symptoms. Coolant pushed out of the degas bottle, a heater blowing cold once hot, overheating while towing or white smoke point to a head gasket or EGR cooler problem, and that job goes much deeper than the covers. Get a diagnosis first, then order the set that matches the job and your dowel size.

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.