Have you been searching to find the most popular ways that people are upgrading and getting more performance out of their 6.0 powered Super Duties?
Well you’ve come to the right place! We love power strokes, and we love to modify them!
Four starters, while everyone wants to talk about how you need to head gasket/stud these trucks the actual instant you buy them, we have seen many times where the trucks were kept within a respectable amount of modification and have held up just fine.
Wait a second, did I accidentally say four starters instead of for starters? Yes, yes I did, but not an accident. If you know, you know. Get yourself a hp gear reduction starter to fix that.
Are the clamping forces as designed terrible at keeping the head gaskets under the heads at high boost? Absolutely. Can it be functionally fixed with head studs? Yep, and there are plenty of kits to do just that if you want to go big turbo and big power.
Still, there are lots of owners just out having fun and getting work done with their perfectly capable (if a little flawed) trucks.
Moving along, anyone who has ever modified a vehicle can tell you – an air intake and an exhaust are easy, inexpensive ways to boost your truck’s power by aforementioned respectable amounts, as modifying these systems allows your truck to breathe way easier and run more efficiently.
Through the process of modding, and then modding again, we have exhausted the options and intaked ( is that a word?) what we believe to be the absolute best of the best.
All compiled in a neat little list of ways to upgrade for your truck. Just scroll down. You’re welcome 🙂
PS, this guide is specifically made for the 6.0L Powerstroke engine in the ’03-07 Ford diesel trucks. If you have a newer truck, check out our guides for the 6.4L and 6.7L Powerstrokes.
Best way to monitor your 6.0’s vitals
In my opinion, the very first thing that is needed to extract the maximum safe horsepower, torque and fuel economy from your truck is a reliable way to instantly monitor your truck’s vitals, to be able to react immediately.
My logic being that if you go into modding you truck without any feedback, and without a good way to monitor what your truck wants to tell you, how could you possibly keep the head gaskets inside the engine where they belong? 😉
Our pick for the best option for the 6.0 is of course the Livewire Vision Peformance monitor. Please note: this is different from the Livewire TS+ Tuner.
SCT Livewire Vision for Ford Powerstroke 7.3, 6.0, 6.4, 6.7 5015P
Ebay.com
Color 4" Touch Screen Display
Livewire Vision features a full color 4" touch screen display with built-in ambient light sensor for automatic brightness adjustment day & night.
Blue Spring Fuel Pressure Upgrade Kit
The blue spring mod is a very popular performance and reliability upgrade for the 6.0, and for a good reason. This simple mod will increase your fuel pressure by around 10-15psi, making your truck run much more smoothly, while decreasing the amount of strain on your injectors.
Bank for your buck it is one of the cheapest and best fuel mods than you can do to these trucks. It is especially a must do if you are going to be adding other power increasing mods to your truck.
6.0 Blue Spring Kit Upgrade - Fuel Regulator Kit - Ford Blue Spring Kit 6.0 Powerstroke F250, F350, F450, F550 2003, 2004, 2005, 2006, 2007 - 3C3Z-9T517-AG
Amazon
Features
- BLUE SPRING KIT 6.0 POWERSTROKE - Increase fuel pressure for increased performance. This upgrade will increase the fuel pressure 10-15psi on your 6.0 powerstroke truck and it lengthens the life of the fuel injectors as well.
- EASY TO INSTALL - The 6.0 powerstroke blue spring kit includes all the gaskets, seals, bolts, spring, and regulator housing needed for installation. This fuel pressure regulator kit includes a detailed installation video (link included in packaging) with step-by-step instructions for the blue spring upgrade.
- COMPATIBLE WITH FORD 6.0L POWERSTROKE TRUCKS - Ford F250, F350, F450, F550 and Excursion model years 2003, 2004, 2005, 2006 and 2007. This is not a genuine OEM part, the term is used only for vehicle identification purposes.
- REPLACES PART# 3C3Z-9T517-AG. Perfect for stock or modified trucks. The 6.0 Blue Spring Kit is a common upgrade because it increases injector life, increases drive-ability, and gives smoother power delivery.
- COMPLETE INSTALLATION KIT - Everything needed for installation on your 6.0 Powerstroke Ford Truck: the blue spring upgrade, 4 rubber o-ring seals, 3 orifice seals, 4 screws, and the fuel pressure regulator housing. This blue spring kit manufactured by AA Ignition comes complete with a lifetime warranty. See our website for full details.
Turbo Back Exhaust
Quite simply, the best turbo back exhaust for the 6.0 powerstroke is a simple straight pipe (no restrictions) from the turbo right out to the back of the truck.
Having the exhaust free of all the factory restrictions has a few great benefits (lower exhaust temps, quicker spooling from the turbo), but by far my favorite two side effects are more horsepower and torque!
One thing to look for to find a good exhaust system: mandrel bends. This simply means that the bends in the exhaust have been made with a die of some kind inserted inside of the pipe at the bending point, to prevent deformation (crushed in sections in the middle of the bend.)
When looking to maximize flow and spool times, you’re going to want to minimize any disturbances in the flow, especially where the exhaust gases have to go around bends and corners. This is the reason why these types of bends are far superior to crush bent exhausts, it simply flows much better because the middle of the bend isn’t all smashed in and interfering with flow. Any good exhaust will always use mandrel bends.
Our favorite for the 6.0 is this one show below. This is the kit that fits on all bed sizes of the ’03-’07 Ford powerstroke trucks.
MBRP 4" Straight Pipe Exhaust For 2003-2007 Ford F-250 F-350 6.0L Powerstroke
Ebay.us
Banks Power Ram-Air Intake System
An air intake kit is possibly the most common modification that people start with when looking for more performance, and the reason is obvious:
Engines need air and fuel to make power. The more air and fuel, the more power, it’s as simple as that. Having a turbocharger like the 6.0 has just makes unrestricted breathing even more important.
Nearly unrestricted breathing is the aim of most aftermarket intakes, and a lot of them do just that. They also all look pretty similar in form too. Since most of them will do the job of opening up the airflow, it basically all comes down to the differences in performance vs reliability, maintenance, and cost.
This Banks intake pulls off the balance between form and function very well. Because of the great Gale Banks design (that actually pulls in cold air) and the reusable dry filters, I would say that it is the best value intake out there for the 6.0 powerstroke. A main concern with a lot of the other aftermarket intake designs is that they leave the filter exposed to the heatsoak of the engine bay. This is a really bad idea, especially with how high the underhood temps can get in these trucks.
The Banks kit solves the underhood temp issue with a filter box that pulls air from outside your engine bay, like an intake always should. This design allows you to visually inspect the filter, and makes it much less of a pain to remove for cleaning vs. the stock setup. The rubber seal that they include blocks airflow around the airbox, making the setup draw even colder air from outside the engine bay.
As far as reliability and maintenance goes, the best part about the dry filters that Banks uses in this kit, is that they can be reused a bunch of times and they never need oiling. All you need is just a soapy wash and water rinse (rinse from the inside out) from time to time. Or alternatively, you can vacuum the filter (from the outside) to get the dirt out, which works well too. But one thing I have learned the hard way with dry filters, NEVER try to clean the filter with compressed air, it ends up ruining the media and you’ll have to buy a new one (my wallet speaks from experience here.)
BANKS 42155 Ram-Air Intake System, 2003-2007 6.0L Ford
Features
| Part Number | M143787833 |
Garrett PowerMax Turbo Upgrade
This turbo is a great power upgrade, if your original turbo needs replacement or you just want up to 175 more horsepower, look no further than the PowerMax. You’ll be able to install this turbo with no more hassle than installing the original Garrett that comes in your truck, it is a true bolt in swap.
Garrett is at the forefront of turbo technology and the attention to detail on the powermax really shows off their innovation. One of the coolest features is the variable vane tech that they’ve incorporated into the design, which restricts down low and opens up top. This greatly increases the turbine’s efficiency as the rpms change, which keeps the boost at peak performance from idle to redline.
Garrett Powermax Turbocharger for 04.5-07 Powerstroke 6.0L Turbo
Features
| Brand | Garrett |
| Catalog Number List | Catalog Number List Element: BDZW772441-5002S |
| EAN | 0681430477541 |
| EAN List | EAN List Element: 0681430477541 |
| Item Dimensions | Height: 0; Length: 0; Weight: 0; Width: 0 |
| Label | Garrett |
| Manufacturer | Garrett |
| Manufacturer Parts Warranty Description | Parts |
| MPN | 772441-5002S |
| Number Of Items | 1 |
| Package Dimensions | Height: 1050; Length: 1400; Weight: 4185; Width: 1140 |
| Package Quantity | 1 |
| Part Number | 772441-5002S |
| Product Group | Automotive Parts and Accessories |
| Product Type Name | AUTO_PART |
| Publisher | Garrett |
| Studio | Garrett |
| Title | Garrett Powermax Turbocharger for 04.5-07 Powerstroke 6.0L Turbo |
| UPC | 681430477541 |
| UPC List | UPC List Element: 681430477541 |
EGR Cooler Upgrade
More preventative than a fun upgrade, this is still a necessity for just about all the old trucks out there with questionable egr coolers. You do not want to have all your coolant blown out of your exhaust, trust me on that one.
Probably is the best value option for upgrading the problematic, clog-prone factory EGR cooler that comes equipped on the 6.0 Powerstroke is this kit below.
This cooler is a huge upgrade to the factory ford EGR cooler. Made from from stainless steel, and some great looking TIG welds, it looks just as good as it performs. Internally, their design ditches the factory ford honeycomb mesh (that without fail always clogs up) and instead uses rounded tubes as the medium.
They pressure test their coolers to ensure that there aren’t any leaks when you install it. Leakproof is absolutely something you want to be sure of when going through all the trouble of installing a cooler replacement. The install itself is a direct replacement fit, so no hacking or modifying of your other EGR components is required.
Upgraded EGR Cooler & Oil Cooler Kit For Ford F-250 350 6.0L Powerstroke Diesel Turbo
Upstand Pipe and Dummy Plug Upgrade Kit
If your truck is having hard start issues after it’s warmed up, you most likely have a leak in the oil system, causing the injectors to not pressurize fully. A very common place for oil pressure to leak out is the seals on the dummy plugs, causing your fuel pressure to be too low to start the truck right away.
If you’ve checked the usual electrical suspects, such as the FICM, IPR and IPC and those are operating as intended, then you most likely have a loss of oil pressure.
A good upgrade kit for replacing the dummy plugs and upstand pipe is this kit, it solves the issues that your original dummy plugs have with worn out or rotten seals, sealing up the oil system which will restore your fuel pressure back to normal.
Features
- genuine oem factory part
- exact fit
- durable
- best in quality
- this is not an aftermarket part
6.4 Starter Upgrade
The perfect upgrade for 6.0 trucks that have a really slow starter is the much better version that comes in the 6.4 and later trucks. Ford revised the gearset in the newer starters which results in much faster cranking times.
It’s a simple drop-in replacement, nothing needs to be modified so this upgrade is a no brainer if your current starter is getting really slow.
DB Electrical SFD0122 New Starter For 6.4L 6.4 Ford F150 F250 F350 Diesel Truck 08 09 10 2008 2009 2010 410-14080 7C3T-11000-AA 7C3T-11000-AB 7C3Z-11002-AA
Features
- PEAK PERFORMANCE: This replacement starter is engineered to deliver peak performance and reliability for increased starting power. The high-quality construction and materials ensure efficient operation, providing the reliable starting performance you need.
- FAST ENGINE STARTER: The DB Electrical starter is designed for fast and efficient engine starters. This starter part for cars features cleaner and drier inner workings with sealed housings that block performance-robbing residue, as well as upgraded copper and silver contacts for enhanced performance.
- DURABILITY: This product features high-quality materials and construction, ensuring durability and longevity even in harsh conditions. The starter replacement is designed for simple and straightforward installation, reducing downtime and labor costs.
- COMPATIBILITY: The DB Electrical 410-14080 starter is compatible with/replacement for FORD: F-250 SUPER-DUTY 2008-2010, F-350 SUPER-DUTY 2008-2010, F-450 SUPER-DUTY 2008-2010, F-550 SUPER-DUTY 2008-2010
- Please check the Amazon Confirmed Fit bar to ensure compatibility with your vehicle. If the confirmed fit bar has an "i" in a blue circle, this product has additional notes. Please hover over the “i” to see notes before making your purchase.
Head Gasket and ARP Stud Kit
The most hardcore of upgrades is replacing the head gaskets and bolts with new gaskets and studs to clamp it all together. Unfortunately this is an upgrade that a lot of 6.0 owners have had to do to, with head gasket issues being a weak link in these trucks.
It’s such a common occurrence that there are now bulletproofing kit options for replacing everything that this job requires, such as intake gaskets and all the other little gaskets that you would normally not think of when ordering, all included in one easy box with brand new ARP studs – which are a must install. The factory bolts just can’t physically have the same clamping force that studs can, and that’s one thing you really need on a high boost 6.0.
The only thing to be aware of when choosing a head gasket kit is the build dates on your tuck. Basically, if your truck was built before January 14th 2006, and has t40 Torx bolts for the injector hold-downs – then you have the 18mm dowels in your heads. Of course you should get the kit that has the head gaskets that fits those dowels.
After January 14th, the 2006 and 2007 heads have 20mm dowels in them. That’s really the only catch as far as ordering kits goes, pay attention there and your parts will fit when you go to put the beast of a job back together.
03-06 Ford Powerstroke 6.0L Diesel ARP Head Stud Kit & OEM Style 18MM Head Gaskets & Intake Manifold Installation Kit & Exhaust Gaskets Kit - Bundle (18MM)
Features
- ARP Studs
- MAHLE Black Diamond Head Gaskets
- Master Intake Gasket Set with Injector O-rings and Turbo Hardware
- Exhaust Manifold Gaskets
Intercooler Piping Upgrade
The factory intercooler boots on the 6.0 are known for being a weak point. After years of sitting on top of the hot engine they often crack and create leaks. The best way to address this is with an intercooler piping upgrade kit such as this one.
Mishimoto MMICP-F2D-03BK Intercooler Pipe Kit Compatible With Ford 6.0 Powerstroke 2003-2007 Black
Features
- Direct fit for the 2003-2007 Ford 6.0L Powerstroke
- Pipe Construction: Polished Aluminum Pipe Diameter: 3.0"
- Improves airflow, power, and EGTs
- Duracore technology provides superior resistance to heat, pressure, fuel, and oil
- Mishimoto Lifetime Warranty
Aluminum Degas Bottle and Y-pipe Upgrade
Another huge failure point on the 6.0 that just about always needs to be addressed is the failure of the coolant cap and the eventual cracking and leaking of the plastic degas bottle.
Fortunately, there are a bunch of aftermarket aluminum degas bottles that solve this issue permanently. My favorite one comes from from Rudy’s Diesel in Ford’s famous any color you want as long as its black.
Don’t fall victim to a head gasket failure because of a simple coolant leak, bulletproof the coolant system before that can happen!
Silver Aluminum Degas Bottle/Coolant Y-Pipe/Gold Antifreeze 03-07 6.0L Powerstroke
Conclusion
We hope this has answered your questions about what performance upgrades to start with for upgrading the performance on your 6.0 Powerstroke. If you have questions, comments or other upgrades that you think should make the list, be sure to let us know in the comments below, thanks for reading!
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just wanted to say thanks for this article this is excellent for the new guys like me out there
Thanks Chad! Glad we could help!
Thanks for the info, I had a 7.3 that was stolen and am looking a 6.0 build now. Your article is very informative, and to the point.
Great job guys.
Thanks for the info.
Lorne
Hey Lorne, thanks for the feedback! We love hearing that our readers are learning useful information from us.
Hello, I have an ’04 CCLB 4×4 F250. Mods are Swamps stock voltage FICM, !EGR, !CAT, engine monitor, ’03 turbo, 7.3 fan clutch, coolant filter, Cat ELC coolant and I think that is about it. It has 200k miles and has never been tuned. Still running original headgaskets. Replaced injectors at 165k. I regularly pull 11-12,000 pounds over steep grades and I have to back off to 45mph or so to keep the temps down (oil and egt). I would like to be able to maintain 65 up the steep stuff if possible. I’m considering a meth kit, perhaps an aftermarket intercooler and radiator. Any thoughts? It isn’t a performance truck. I travel for work and it drags my home away from home. Last night I towed a steep grade and even at 45 I briefly hit 121 degrees oil temp. My temp deltas are about 8 degrees flat and level at 60-65 mph. Sensors are good.
Cheers,
Jon
If you are running a good synthetic like Rotella T6, short bursts (10-20mins) of oil temp up to 230 degrees F will not be a problem. If you are really worried, look into a BPD Air cooler upgrade.
its no wonder everything i found what i have been looking for. Thank you Jeff hart
Glad we could give you the info you were looking for!