6.0 Power Stroke Maintenance Guide

Page Contents:

  1. 6.0 Power Stroke Maintenance Schedule (Normal Conditions)
  2. 6.0 Power Stroke Maintenance Schedule (Severe Conditions)
  3. 6.0 Power Stroke Oil Viscosity Chart
  4. 6.0 Power Stroke Oil & Fluid Specifications
  5. 6.0 Power Stroke Oil & Fluid Capacities
  6. Relevant Service Part Numbers

Applicable Models:

2003 - 2007 Ford F-250, F-350, F-450, F-550 Super Duty
2003 - 2005 Ford Excursion
2004 - 2010 Ford Econoline E-350
2003 - 2008 Ford F-650, F-750 medium duty trucks

Applicable Engine(s):

6.0L Power Stroke diesel V-8

Application Transmissions:

Ford 5R110W TorqShift five speed automatic
ZF S6-750 six speed manual

Applicable Drivetrain:

2 wheel drive and 4 wheel drive models

6.0 Power Stroke Maintenance Schedule

The maintenance schedule for "normal" driving conditions assumes the vehicle is driven unladen in ideal traffic conditions with minimal engine idling and constant road speeds. A vehicle will fall under the "severe" or "heavy duty" service category if it meets any of the following criteria:

• Vehicle is idled frequently and/or excessively (generally defined as 10 minutes or more idling within a 1 hour window)
• Vehicle makes frequent short trips in which the engine often shutdown repeatedly before reaching full operating temperature
• Vehicle is driven off-road or in conditions that require the 4 wheel drive to be engaged
• Vehicle experiences light towing/hauling in excess of 1,000 miles between oil change intervals
• Vehicle tows and/or hauls medium to heavy loads
• Engine is run on biodiesel or biodiesel blends (any concentration)

As a general rule-of-thumb, most owners of a heavy duty pickup truck or van will fall under the severe/heavy duty service category, requiring an alternative maintenance schedule calling for more frequent service procedures. If in doubt about which service category your vehicle falls under, always adhere to the more stringent severe/heavy duty service intervals.

Many service intervals are provided in distance driven OR a period of time; service should be performed when either of these two conditions are met, whichever comes first.

Normal Service Intervals

Service Procedure

Service Interval(s)

Replace engine oil & oil filter

Every 7,500 miles/6 months

Replace fuel filter

Every 15,000 miles

Replace engine air filter

Monitor air filter minder (mounted to air filter housing), replace as necessary

Flush/service engine cooling system

100,000 miles/5 years initially
Every 45,000 miles/36 months thereafter

Replace automatic transmission fluid & filter

Every 30,000 miles

Replace manual transmission fluid

Every 60,000 miles

Replace transfer case fluid

Every 150,000 miles [1]

Replace front differential fluid (4x4)

Every 100,000 miles [1]

Replace rear differential fluid

Every 100,000 miles [1]

[1] - Replace oil/fluid as soon as possible if component is submerged in water; water intrusion highly probable.

Severe/Heavy Duty Service Intervals

Service Procedure

Service Interval(s)

Replace engine oil & oil filter

Every 5,000 miles/6 months

Replace fuel filter

Every 15,000 miles when using conventional diesel fuel
Every 7,500 miles when using biodiesel blends exceeding B5 (5% biodiesel)

Replace engine air filter

Monitor air filter minder (mounted to air filter housing), replace as necessary

Flush/service engine cooling system

100,000 miles/5 years initially
Every 45,000 miles/36 months thereafter

Replace automatic transmission fluid & filter

Every 30,000 miles

Replace manual transmission fluid

Every 60,000 miles

Replace transfer case fluid

Every 60,000 miles [2]

Replace front differential fluid (4x4)

Every 30,000 miles [2]

Replace rear differential fluid

Every 30,000 miles [2]

[2] - Replace oil/fluid as soon as possible if component is submerged in water; water intrusion highly probable.

6.0 Power Stroke Oils, Lubricants, & Fluids

Engine Oil Viscosity Chart

6.0L Power Stroke oil viscosity chart with ambient temperature ranges

6.0 Power Stroke engine oil viscosity chart

An engine oil viscosity grade should be selected based on the expected ambient temperature range in which the vehicle is to be operated. Due to the 6.0L Power Stroke's EGR system, an engine oil that meets API CI-4/CH-4 specifications is required. Note that certain viscosity grades are listed as "acceptable" within a temperature range while others are listed as "preferred". When possible, select an engine oil viscosity that is listed as preferred within the expected temperature range.

For most applications, SAE 15W-40 engine oil is recommended. We highly recommend a high quality synthetic motor oil due to its resilience against degradation and oxidation in engines employing an HEUI injection system. Synthetic motor oils will provide improved wear protection under the strenuous oil pressures these systems endure.

Oil & Fluid Specifications

Fluid Type

Oil/Fluid Specification

Remarks

Engine oil

SAE 15W-40 preferred in ambient temperatures > 30° F
Recommend Amsoil Max Duty Signature Series 15W-40 diesel oil

[3]

SAE 10W-30 preferred in ambient temperatures between -10 to 30° F
Recommend Amsoil Max Duty Signature Series 10W-30 diesel oil

SAE 5W-30 acceptable in ambient temperatures < 30° F

SAE 0W-30 acceptable in ambient temperatures < 0° F

Engine Oil API Category:

CI-4/CH-4 or equivalent

---

Engine coolant

Motorcraft VC-7-B Gold concentrated engine coolant mixed 50/50 with distilled water
Motorcraft VC-7DIL-B Gold prediluted engine coolant (do NOT add water)

---

Automatic transmission fluid

Motorcraft MERCON SP ATF (XT-6-QSP)

---

Manual transmission fluid

Motorcraft MERCON V ATF (XT-5-QMC)
Recommend Amsoil Signature Series Synthetic ATF

---

Transfer case fluid

Motorcraft MERCON LV ATF (XT-10-QLVC)
Recommend Amsoil FE Synthetic ATF as a high quality, full synthetic alternative

[4]

Front differential gear oil

SAE 80W-90 gear oil or SAE 90W hypoid gear oil
Recommend Amsoil Severe Gear 80W-90 synthetic gear oil

---

Rear differential gear oil

Sterling 10.50

SAE 75W-140 full synthetic gear oil
Recommend Amsoil Severe Gear 75W-140 synthetic gear oil

[5]

Dana 80

SAE 75W-90 full synthetic gear oil
Recommend Amsoil Severe Gear 75W-90 synthetic gear oil

Dana S135

SAE 80W-90 gear oil
Recommend Amsoil Severe Gear 80W-90 synthetic gear oil

Dana S110/S130

SAE 75W-140 full synthetic gear oil
Recommend Amsoil Severe Gear 75W-140 synthetic gear oil

Limited slip additive

Motorcraft XL-3 friction modifier

Brake fluid

Motorcraft PM-1 DOT 3 brake fluid
Recommend Amsoil DOT 3 synthetic brake fluid

---

Clutch hydraulic fluid

Power steering fluid

Motorcraft MERCON V ATF (XT-5-QMC)

---

[3] - Refer to viscosity chart for complete viscosity grade application details; be mindful of the terms "preferred" and "acceptable". When possible, select a viscosity grade that is preferred within the expected ambient temperature range in which the vehicle is being operated.
[4] - MERCON LV replaces prior Motorcraft XL-12 transfer case fluid specification.
[5] - Limited slip differentials may require a friction modifier to prevent chatter; use Motorcraft XL-3. Sterling 10.50 used in single rear wheel applications only. Dana 80, S110, S130, and S135 rear differentials used in dual rear wheel applications only.

Oil & Fluid Capacities

Fluid Type

Oil/Fluid Capacity

Remarks

Engine oil

15.0 U.S. quarts

[6]

Engine coolant

6.875 gallons

---

Automatic transmission fluid

17.5 U.S. quarts

[7]

Manual transmission fluid

5.8 U.S. quarts

[8]

Transfer case fluid

2.0 U.S. quarts

[8]

Front differential gear oil

3.0 U.S. quarts

[8]

Rear differential gear oil

Sterling 10.50

3.45 U.S. quarts

[8],[9]

Dana 80

4.25 U.S. quarts

Dana S135

12.25 U.S. quarts

Dana S110/S130

8.4 U.S. quarts

Brake fluid

N/A; fill to reservoir marker

---

Clutch hydraulic fluid

N/A; fill to reservoir marker/line

---

Power steering fluid

N/A; fill to correct dipstick level

---

[6] - Engine oil refill capacity with lube oil filter change
[7] - Total transmission fluid capacity listed; actual service refill capacity significantly less, add fluid through dipstick tube until appropriate dipstick level indicator range has been reached
[8] - Fill component until oil has reached the lower level of the fill plug hole; fill plug height is the appropriate lubricant level indicator. When checking fluid level, oil should be no less than 1/4 inch below the fill plug opening. Always fill and check fluid level with vehicle parked on level ground.
[9] - If friction modifier/additive is required for limited slip differential, add before filling with gear oil. Dana 80, S110, S130, and S135 rear differentials used in dual rear wheel applications only.

6.0 Power Stroke Service Parts List

Part Description

Part Number(s)

Engine air filter

Motorcraft FA-1778 (Ford 4C3Z-9601-AA)

Engine oil filter

Motorcraft FL-2016 (Ford 3C3Z-6731-AA)

Oil filter housing cap/lid

Motorcraft EC-781 (Ford 3C3Z-6766-CA)

Engine oil fill cap

Motorcraft EC-743 (Ford F3AZ-6766-B)

Oil pan drain plug

Ford 8C3Z-6730-A

Fuel filter set

Motorcraft FD-4616 (Ford 3C3Z-9N184-CA, includes engine & chassis filters, o-rings)

Fuel filter housing cap/lid

Ford 3C3Z-9G270-AA

EGR valve o-ring set

Ford 3C3Z-9P455-AB

Serpentine belt

Motorcraft JK81267A (Ford 3C3Z-8620-DB, single alternator)

Glow plug [10]

2003 - early 2004

Motorcraft ZD-12 (Ford 3C3Z-12A342-AA), see warning [10]

2004 - 2007

Motorcraft ZD-13 (Ford 4C3Z-12A342-AA, set of 8)

Thermostat

Motorcraft RT-1169 (Ford 3C3Z-8575-AA)

Thermostat housing gasket

Ford 3C3Z-8255-AA

Radiator overflow/degas cap

Ford 9C3Z-8101-B

Upper radiator hose

Motorcraft KM4783 (Ford 3C3Z-8260-AG)

Lower radiator hose

Motorcraft LM4784 (Ford 3C3Z-8286-AJ)

Camshaft position sensor (CPS)

Ford 8C3Z-12K073-A

Crankshaft position sensor (CKP)

Ford 3C3Z-6C315-AA

Exhaust backpressure sensor (EBP)

2003 - 2004 [11]

Motorcraft DPFE-3 (Ford 4C3Z-9J460-A)

2005 - 2007

Ford 5C3Z-9J460-B

Injector control pressure sensor (ICP)

2003 - early 2004 [12]

Ford 3C3Z-9F838-EA

2004 - 2007

Ford 4C3Z-9F838-A

ICP sensor pigtail

Ford 5C3Z-12224-A
REID TEKK RT-150701

Injection pressure regulator (IPR)

2003 - early 2004

Ford 3C3Z-9C968-AA

2004 - 2007

Ford 5C3Z-9C968-CA

Automatic transmission filter
(TorqShift 5R110W, 5 spd)

Primary filter

Motorcraft FT-144 (Ford 3C3Z-7A098-AA)
(internal transmission filter)

Auxiliary filter

Motorcraft FT-145 (Ford 3C3Z-7B155-BA)
(external, frame mounted filter)

[10] - 6.0 Power Stroke pistons were redesigned for the 2004 model year, requiring a shorter glow plug. Early glow plugs CANNOT be used in later engines as they WILL contact the piston and cause severe engine damage. Engines built after 9/29/2003 received the new piston design and are considered late 2004 engines. Note that early 2004 model year vehicles received 2003 model year engines, so you must refer to the engine build date, not the vehicle build date.
[11] - 2003 and early 2004 model year engine calibrations use an inferred exhaust backpressure reading; the sensor is not used by the PCM and should not require replacement.
[12] - The ICP sensor on 2003 and early 2004 model year trucks is located behind the turbocharger next to the IRP valve. Late 2004 and later engines have the ICP sensor located through the passenger side valve cover. The ICP sensors are physically different for early and late model engines.