2004 Ford E-450 Super Duty

Reliability tier: verified - see /disclosure/

Engine: 6.0L (Power Stroke, 6.0L)

head dowel: 18mm (E-Series engines built before the 2006-01 dowel change). Late-2004 build ('2004.5') engines received the 2005-spec HPOP with the STC snap-to-connect fitting (STC fitting (high-pressure oil rail) failure); 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 (30)

• 6.0L Power Stroke Battery, Group 65 (Ford BXT-65-750, paired)
• 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 Pressure Cap
• 6.0L Power Stroke EGR Cooler, square-style 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
• Engine oil and filter service, CJ-4/CK-4 15W-40 (or 5W-40 full synthetic in cold climates)
• 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
• Head O-ring / fire-ring machining service (machine shop, per head)
• 6.0L Power Stroke Cylinder Head Stud Kit (ARP 2000)
• 6.0L Power Stroke ICP Sensor (Injection Control Pressure)
• 6.0L Power Stroke Remanufactured Fuel Injector, stock HP (XDP XD470, 2003-2004)
• 6.0L Power Stroke Remanufactured Fuel Injector, stock HP (XDP XD471, 2004.5-2007)
• 6.0L Power Stroke IPR Valve (Injection Pressure Regulator) with screen & o-rings
• 6.0L Power Stroke Oil Cooler Service: HPOP Inlet Screen + Seals
• 6.0L Power Stroke Engine Oil Cooler (valley, oil-to-coolant)
• 6.0L Power Stroke Oil Filter Cartridge Kit (Ford 3C3Z-6731-AA, 2003-2007)
• 6.0L Power Stroke Regulated Return Fuel System Kit (Driven Diesel, 2003-2007)
• Stiction-reducing oil additive (service item, stopgap only)
• 6.0L Power Stroke Thermostat
• 6.0L Power Stroke VGT Turbocharger (reman / upgraded)
• 6.0L Power Stroke Water Pump

Platform recipes (6)

• 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
• FICM diagnosis and repair (mode fm-6-0-ficm-failure): the Fuel Injection Control Module's 48V rail sags with age - misfires, hard starts and stiction-mimic symptoms
• Preventive baseline for a stock, healthy 6.0 with no current failures
• Injector stiction repair (mode fm-6-0-injector-stiction): rough cold start and smoking that clears hot - the oil-side story of tired HEUI injector internals plus marginal oil pressure
• For a stock-power 6.0 used to tow, with no full bulletproof budget yet

Recalls that include this truck (1)

• 05V-270 (June 10, 2005) - ELECTRICAL SYSTEM:WIRING: CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.

Matched by the model and model year NHTSA lists for each recall - a recall often covers only part of a year's production, so read its text for the build dates and versions it names. Whether a recall is still open on your VIN is not known here; check nhtsa.gov/recalls. All recalls, investigations and bulletins for this engine: /recalls/powerstroke-6_0/

Reference for this truck