DieselPowerUp

Find the right performance parts to take your truck to the next level. We can guide you through all kinds of modifications, from DPF/DEF deletes to the best lift kits, and much more...

  • Home
  • Contact
  • About
  • Privacy Policy

Best Upgrades for the 7.3L Power Stroke

Updated August 7, 2024 by Jeff Hart

Best Upgrades for 7.3L Power Stroke

The 7.3L Powerstroke is commonly regarded as possibly the best Powerstroke engine that Ford has made to date. It wasn’t plagued with the head gasket problems of the 6.0L Powerstroke, nor was it weighed down by the emission issues that were found in the 6.4L Powerstroke and the 6.7L Powerstroke. These factors and more allow the 7.3 to have incredible reliability and power capability, making it an excellent powerplant that lasts for a very long time.

My praises for the 7.3 aside, we all know how good it is, but there are still a few things that can be done to improve it beyond what Ford engineered it to do. The best mods for these engines have to do with reliability, adding power, and improving MPGs. A lot of them are quite simple, effective, and cheap, and will work wonders to transform your truck to another level of performance.

We came up with his guide to categorize the most popular mods for the 7.3L. In the name of keeping it simple, it starts with the most popular mods to do, the ones that have the most impact on performance and goes down the list from there. You can also use the table of contents below to skip to whatever mod you might be interested in most.

Best Intake Kit for the 7.3L

  • S&B Filters Cold Air Intake (Reusable Filter)

There is not much else (for the cost) that can wake up your truck like a new cold air intake. This S&B intake is probably the best that we’ve used for the 7.3L Powerstroke, it offers such a great return on investment as far as smiles per gallon go. A cold air intake is crucial for a starting mod, as it allows the engine to pull in a much higher volume of air, setting you up for success later down the line when you increase boost and lower backpressure. 

aFe Power Magnum FORCE 54-10792 Ford Diesel Truck 94-97 V8-7.3L (td) Performance Intake System (Oiled, 5-Layer Filter)

aFe Power Magnum FORCE 54-10792 Ford Diesel Truck 94-97 V8-7.3L (td) Performance Intake System (Oiled, 5-Layer Filter)

Check Price
Amazon
as of May 6, 2025 8:48 pm

Features

  • Open intake design for added power and sound
  • Dyno-proven gains and improved throttle response
  • Massive air filter with Pro 5R oiled cotton media for maximum air flow
  • This item is 50-State legal: CARB EO# D-550-4

Best Exhaust Kit for the 7.3L

  • Magnaflow Turbo Back Single Side Exhaust System

Once you have the volume of air into the engine increased from upgrading to a high flow cold air intake, you’ll need to upgrade the flow out of the engine through the exhaust to match. A larger exhaust exhaust with smoother bends allows you to do this, by reducing the amount of backpressure behind the turbo. As we all know, combustion engines are basically complicated air pumps. The more air that you can pull in and then pump out, the more power can be made. It also increases the efficiency of the burn, if you upgrade the fueling to match.  

4" Turbo Back Exhaust for 7.3L Powerstroke

4" Turbo Back Exhaust for 7.3L Powerstroke

Check Price
Ebay.us
as of May 6, 2025 8:48 pm

A huge performance upgrade for the 7.3L Powerstroke, this exhaust system allows for maximum flow and minimum turbo backpressure, making your truck run more efficiently and with more power!

Key Features:

Delivers an Aggressive, Deep Exhaust Note
Includes Maximum Flow Muffler Delete Pipe
Installs with Common Hand Tools
Boosts Torque and Horsepower
Maximum Performance at a Minimum Price
Not for Use on Vehicles Equipped with a Catalytic Converter
1 Year Manufacturer’s Warranty

Best Tuner Chip for the 7.3L

  • TS Performance 6-way Switchable Tune

All the higher flow upgrades that you add to your truck are not going to do you nearly as much good until you adjust the fuel and burn to take full advantage of the added air. Fortunately for the 7.3L this is both easy and cheap to do, with a TS Performance chip. Simply plug the chip into your trucks PCM, and then run the wire for the tune selector to an easy to reach place by the steering wheel. The 6-position selector switch actually has 8 total options and allows you to change between the pre-loaded tunes as follows:

  1. Valet Mode for when you don’t want a driver to have full power
  2. Stock Mode for normal driving
  3. High-Idle Mode to allow you quickly warm up your truck 
  4. Anti-Theft Mode for added protection
  5. 50 HP mode increases the wheel horsepower by 50
  6. 75 HP mode of course is a 75 horsepower increase
  7. 100 HP mode starts to add quite a bit of power at 100 more hp
  8. 140 HP mode will be where you need to start adding supporting mods
TS Performance Part # 1180402 Diesel Performance Horsepower/Fuel Economy Switchable Chip

TS Performance Part # 1180402 Diesel Performance Horsepower/Fuel Economy Switchable Chip

Check Price
Amzn.to
as of May 6, 2025 8:48 pm

Features
Detailed Instructions Included
All HP Settings are RWHP
Easy Installation
In Cab Adjustable
Hardware and Programming are TS Performances' Design

Best Gauges for the 7.3

  • GlowShift complete gauge kit

If you have started upgrading and tuning your 7.3L, the most important thing that you can to preserve the heath of your engine is to monitor the vitals. In order of importance, the most critical things to monitor on any diesel are the EGT’s (exhaust gas temperatures) the boost pressure, and the transmission temperature (especially if towing.) This gauge set allows you to do that in one easy to install package.

GlowShift 1999-2007 Ford Superduty Tan Gauge Package Black Face Boost, EGT & Trans Temp

GlowShift 1999-2007 Ford Superduty Tan Gauge Package Black Face Boost, EGT & Trans Temp

Check Price
Amazon
as of May 6, 2025 8:48 pm

Features

  • GlowShift Diesel Gauge Package for the 1999-2007 Ford Super Duty 7.3L 6.0L Power Stroke F250 F350 Truck features a Factory Color Matched Tan Triple Pillar Pod, Black 7 Color Series 3 Gauge Diesel Set, Boost MAP Line T-Fitting Adapter, 3 Gauge Power/Sensor Wiring Harness & an Installation Guide that Walks Users Through the Process of Installing the Gauges, Sensors & Pod Step-By-Step
  • Includes 60 PSI Boost Gauge with 1/8-27 NPT Compression Fittings, 9' Nylon Boost Hose & Boost MAP Line T-Fitting Adapter - 1500°F Pyrometer EGT Gauge with 1/8-27 NPT EGT Probe with 3' of Wire, 6' Sensor Harness & 2' Power Harness - Transmission Temperature Gauge with 1/8-27 NPT Temperature Sensor & 2' Power/Sensor Harness - Black 7 Color Series Features a Black Dial, Clear Lens, 7 Solid Color Modes & 2 Color Cycle Modes
  • Factory Color Matched Tan Triple Pillar Pod for 1999-2007 Ford Super Duty 7.3L 6.0L Power Stroke F250 F350 Trucks Mounts 3 Gauges to the Truck's A-Pillar - Overlay Design Mounts Pod on Top of the Factory A-Pillar - Manufactured from ABS Plastic - UV Protected - Includes Mounting Hardware
  • Includes Ford Super Duty 7.3L 6.0L Power Stroke Installation Guide Complete with Step-By-Step Instructions & Photos that Help Walk You Through the Process of Installing & Wiring this Diesel Gauge Package to Your Truck
  • GlowShift Guarantee with One Year Limited Warranty & Free Lifetime Technical Support

Turbocharger Upgrade for 7.3L

  • Garrett Powermax GTP38R Ballbearing Turbocharger

The best turbo upgrade that you can do for your 7.3L is to swap over to this Garrett ball-bearing monster. With this upgrade, you can replace your tired original turbo with one that can spool much faster and supply significantly more boost throughout the entire rev range, giving you more power and torque.

Garrett Powermax GTP38R Ballbearing Turbocharger for Powerstroke 7.3L

Garrett Powermax GTP38R Ballbearing Turbocharger for Powerstroke 7.3L

Check Price
Amazon
as of May 6, 2025 8:48 pm

Features

  • Patented Garrett dual ball-bearing cartridge
  • Complete bolt-in kit
  • Patented Garrett dual ball-bearing cartridge

AIH Delete Mod

  • Air Intake Heater Boost Plug Sensor Thread Adapter

This mod allows you to remove the restrictive air intake heater out of the flow of incoming boost.

This heater is only activated at low ambient temps while the truck is idling for an extended time, so 90% of drivers won’t even know its gone. The conditions for when it runs are as follows: oil temps below 131°F, glow plugs off, trans in park/neutral, parking brake on, charging system between 11.5 and 15.0 volts, and ambient temp below 32°F.

For how little it runs, it’s a lot better to pull that big heater element out and replace it with this plug, which also allows you to easily add an aftermarket boost pressure sensor.

GlowShift Fuel Pressure Sensor Thread Adapter Compatible with 7.3L Ford F-250 F-350 Super Duty Power Stroke Diesel 1999-2003 - Installs to The Fuel Filter Housing - includes O-Ring

GlowShift Fuel Pressure Sensor Thread Adapter Compatible with 7.3L Ford F-250 F-350 Super Duty Power Stroke Diesel 1999-2003 - Installs to The Fuel Filter Housing - includes O-Ring

Check Price
Amazon
as of May 6, 2025 8:48 pm

Features

  • GlowShift Fuel Pressure Sensor Thread Adapter Allows Users to Install a Fuel Pressure Sensor to the Fuel Filter Housing
  • Compatible with 1999-2003 Ford Super Duty 7.3L Power Stroke
  • Features a 1/8-27 NPT Female Thread Port & O-Ring for a Leak-Free Seal
  • Includes Step-By-Step Installation Instructions
  • GlowShift Guarantee with One Year Limited Warranty & Free Lifetime Technical Support

Filed Under: Guides, Power Stroke

How-To: Add a tailgate assist to your truck

Updated February 22, 2024 by Jeff Hart

tailgate dampener assist

Have you ever had your hands full while trying to open your tailgate? If so, you’ll already realize that if you don’t hold it on the way down, you’ll be greeted with a big slam as your tailgate freefalls – until the cables catch it and jerk it to a hard stop.

This not nice and easy on the cables or the mounting hardware of the gate. Fortunately, there is a way to fix this issue and have a nice and smooth opening tailgate, without you having to hold onto it all the way down.

Tailgate Assist Damper
DeeZee Tailgate Assist Damper

The answer to the dropping tailgate is a simple little hydraulic damper, or assist. These little shock absorbers (or struts) attach directly to the tailgate and bed, slowing the tailgate down for a nice and easy descent.

There are a few manufacturers that make these tailgate dampers, and below I’ll go over the best options and deals for each of the different model trucks listed. If you are installing one of these assists yourself, you’ll find that it’s pretty straightforward for the most part, installation difficulty for most of these kits is about a 3-4 out of 10.

Tailgate assist for the 2015-2017 Ford F-150

  • Ford OEM Tailgate Assist Kit FL3Z-99406A10-A

Without a doubt the best tailgate damper kit that you can get for the 2105, 2016 and 2017 Ford F-150 would be the one made by Ford. It’s designed to fit directly into factory mounting points, so no messing with aftermarket accessory fitment, which can be tricky in some cases.

Genuine Ford FL3Z-99406A10-A Tailgate Shock Assembly

Genuine Ford FL3Z-99406A10-A Tailgate Shock Assembly

Check Price
Amazon
as of May 1, 2025 12:17 am

Features

  • Product Type:Auto Part
  • Item Package Weight:0.771 Kilograms
  • Item Package Dimension:10.668 cm L X15.24 cm W X19.304 cm H
  • Country Of Origin: United States

Tailgate assist for the 2005-2014 Ford F-150

  • DeeZee F-150 Tailgate Assist DZ43200

If you own a 2005-2014 F-150 then the best option for a tailgate damper is this retrofit model by DeeZee. The kit comes with everything you need to add it to your truck, including the strut and all required hardware. Only one damper is needed, there’s no need for a second kit.

Dee Zee DZ43200 Tailgate Assist

Dee Zee DZ43200 Tailgate Assist

Check Price
Amazon
as of May 1, 2025 12:17 am

Features

  • This tailgate assist fits 2004-2014 Ford F150 and 2004-2014 Lincoln Mark LT. Does not fit Flareside Models.
  • NEW and IMPROVED – We have improved the nutsert. You no longer have the little bottle of blue thread lock to mess with. The nutsert comes with thread lock on it and ready to be installed. You do not have to worry about applying the thread lock and getting it on your fingers, clothes, or your vehicle.
  • Easy to use. The Dee Zee tailgate assist makes the use of your tailgate an ease. By simply installing this on your truck will give you the ability to release the tailgate with one hand and not have to worry about that loud bang when it comes down. The smooth controlled drop allows your children to safely lower the tailgate.
  • By adding the heavy-duty tailgate assist to your truck will ease the strain on the cables and hinge point by not free falling. You also will no longer draw attention to yourself when everyone hears the bang as your tailgate slams down.
  • Installation is a breeze NO DRILLING required and the parts are all specific to the year, make, and model truck.

Tailgate assist for the Ford F-250 and F-350 Super Duty

  • DeeZee Tailgate Assist kit DZ43203

This kit is the one designed for the 1999-2106 Ford Super Duty trucks. Just like the other kits from Dee Zee, this one includes all required hardware and installation instructions in the box.

Dee Zee DZ43203 Tailgate Assist Shock

Dee Zee DZ43203 Tailgate Assist Shock

Check Price
Amazon
as of May 1, 2025 12:17 am

Features

  • this tailgate assist fits 1997-2003 ford f150 and 1999-2016 ford super duty f250/f350. it will not fit the f150 supercrew or flareside models.
  • new and improved – we have improved the nutsert. you no longer have the little bottle of blue thread lock to mess with. the nutsert comes with thread lock on it and ready to be installed. you do not have to worry about applying the thread lock and getting it on your fingers, clothes, or your vehicle.
  • easy to use. the dee zee tailgate assist makes the use of your tailgate an ease. by simply installing this on your truck will give you the ability to release the tailgate with one hand and not have to worry about that loud bang when it comes down. the smooth controlled drop allows your children to safely lower the tailgate.
  • by adding the heavy-duty tailgate assist to your truck will ease the strain on the cables and hinge point by not free falling. you also will no longer draw attention to yourself when everyone hears the bang as your tailgate slams down.
  • installation is a breeze no drilling required and the parts are all specific to the year, make, and model truck.

Tailgate assist for the Dodge Ram 1500-3500

  • DeeZee Tailgate Assist kit DZ43301

If you own a Ram 1500 from 2009-2017 or a Ram 2500 and 3500 from 2010-2017, then this is the tailgate assist made specifically for your truck. As always, DeeZee has provided a Dodge Ram specific all-in-one kit that includes everything you will need for am easy, complete install.

Dee Zee DZ43301 Tailgate Assist Shock

Dee Zee DZ43301 Tailgate Assist Shock

Check Price
Amazon
as of May 1, 2025 12:17 am

Features

  • Dee Zee DZ43301 RAM Tailgate Assist / ‘09-‘18 RAM 1500 / 2019+ RAM 1500 Classic / 2010+ RAM 2500/3500
  • NEW and IMPROVED – We have improved the nutsert and it’s ready to go out of the box! The nutsert comes with thread lock on it and ready to be installed. Avoid the mess and install in less steps.
  • The Dee Zee Tailgate Assist makes the use of your tailgate an ease. The simple device allows you release the tailgate with one hand for a controlled drop rate and not have to worry about that loud bang.
  • By adding the heavy-duty Tailgate Assist to your truck will ease the strain on the cables and hinge point by not free falling.
  • Installation is a breeze NO DRILLING required and the parts are all specific to the year, make, and model truck. Utilize the vehicle application checker.

Tailgate assist for the Chevy/GMC 1500, 2500 and 3500HD

  • DeeZee Tailgate Assist kit DZ43102

In the more recent model years, the Chevy trucks have finally started to include a tailgate dampening system in the higher trim trucks like the SLE/SLT and LT/LTZ packages. However if you have an older truck or a base model, you were out of luck as far as having this installed from the factory.

Thankfully, once again DeeZee steps up to the plate to offer their all-in-one kit for GM trucks. This is certified to fit the 2009-2017 1500/2500/3500 and is more of a universal kit that can be adapted to a lot of the Chevy/GMC platform tailgates.

Dee Zee DZ43102 Black Tailgate Assist

Dee Zee DZ43102 Black Tailgate Assist

Check Price
Amazon
as of May 1, 2025 12:17 am

Features

  • This tailgate assist fits on your 2007-2018 Chevy/GMC 1500 and 2007-2019 HD 2500/3500.
  • NEW and IMPROVED – We have improved the nutsert. You no longer have the little bottle of blue thread lock to mess with. The nutsert comes with thread lock on it and ready to be installed. You do not have to worry about applying the thread lock and getting it on your fingers, clothes, or your vehicle.
  • Easy to use. The Dee Zee tailgate assist makes the use of your tailgate an ease. By simply installing this on your truck will give you the ability to release the tailgate with one hand and not have to worry about that loud bang when it comes down. The smooth controlled drop allows your children to safely lower the tailgate.
  • By adding the heavy-duty tailgate assist to your truck will ease the strain on the cables and hinge point by not free falling. You also will no longer draw attention to yourself when everyone hears the bang as your tailgate slams down.
  • Installation is a breeze NO DRILLING required and the parts are all specific to the year, make, and model truck.

What do the truck owners have to say?

DeeZee has made quite the good name for themselves in the truck accessories market, and you can see that in their reviews, which reflect a lot of praise for their products.

Like anything aftermarket, there will always be a couple of hiccups in how the product fits initially or wears over time. This is standard for all aftermarket accessory manufacturers and doesn’t necessarily mean that the products are junk if they have a couple of issues across a wide range of models.

What really matters is how the company handles feedback from their customers about issues that need resolving in the next iteration of the product, and also how they handle the current customers that have the issues in the first place.

Below, you’ll see how they’ve dealt with the only real problem with the DeeZee assist kits and how they have resolved the issue going forward.

 Tailgate assist common problems

The early versions of the Dee-Zee assist in particular did have a frustrating issue that has since been fixed. The issue is with the nutsert that they provided to install the strut with. The nutsert allows you to add threads to a bare hole in your tailgate that wasn’t originally designed to have threads in it.

The problem is that the early version nutsert had a tendency to loosen up in the hole with the repeated rotation that the end of the strut subjects it to. Either the nutsert was just a little off in size, or didn’t have enough friction to hold itself in the tailgate.

Good news is that Dee-Zee has realized the issue, and eliminated the nutsert problem for all the new versions of their kits, and has even been assisting previous customers in fixing the original version.

Conclusion

Hopefully this overview and guide for the options available to add a tailgate assist have helped you in the search for the right kit for your truck. As always, feel free to reach out to us in the comments below if you have any questions or something to add to the conversation. Thanks for reading!

Filed Under: Guides

How To Fix The Missing Fuel Cap on Rams

Updated February 22, 2024 by Jeff Hart

Starting in 2013 and continuing still to this day, the Dodge Ram 1500, 2500 and 3500 turbo diesel trucks all have a pretty significant design flaw.

Yep, that’s a fuel filler that comes from the factory with no cap. A cap-less fuel filler design, really?

What were you thinking Dodge!?

How exactly is the mediocre seal on the fuel door supposed to protect against water and dirt getting into the fuel filler neck?

Of course, Dodge will not admit to this being anything other than the design as intended, but they did release a part number for the people that inquired about missing “gas” caps; the Mopar part# 52029561AA, which is a quite thin and cheaply made green plastic wedge style cap. These do not seem to be durable at all, and still are questionable in their ability to keep out contaminants.

Fortunately, there are a couple options aside from what Dodge has (or hasn’t) provided:

Aluminum Fuel Cap

Thankfully the aftermarket has seen this issue and noticed that people in fact actually want to seal their fuel filler necks from getting crap down into the tank.

The main problem that you’ll have when trying to add a normal fuel cap to one of these dodge trucks – there just isn’t enough room for a regular old gas cap to sit in there and still have the fuel door close.

This is why these billet aluminum caps have such a low profile, so that they can actually fit perfectly in the filler, seal it with an o-ring and still have space for the door to close.

2013-2017 Dodge Ram Diesel Fuel Cap Billet Aluminum Magnetic NEW EASIER GRIP DESIGN

2013-2017 Dodge Ram Diesel Fuel Cap Billet Aluminum Magnetic NEW EASIER GRIP DESIGN

Check Price
Amazon
as of May 5, 2025 8:50 pm

Features

  • Aluminum Construction

Fuel And DEF Cap Combo

If you would prefer a more uniform look, there is a combo set available that combines the DEF and fuel cap replacements together in one kit.

Ram Diesel Fuel Cap and Aluminum DEF Cap Combo for 2013-2018 Dodge Ram Truck 1500 2500 3500

Ram Diesel Fuel Cap and Aluminum DEF Cap Combo for 2013-2018 Dodge Ram Truck 1500 2500 3500

Check Price
Amazon
as of May 5, 2025 8:50 pm

Features

  • ►Easy to grip:With gloves in winter. Hidden-Strong magnetism:Can't see the magnet, let alone be afraid of falling into the fuel tank.
  • ►Compatibility Vehicles - Both fuel caps fit 2013 2014 2015 2016 2017 2018 Dodge Ram 1500 2500 3500 diesel trucks with a cap less fuel system, Cummins and Eco-diesel vehicles with 3.0L V6 engines
  • ►Airtight & Precision Fit - Our diesel fuel caps are well sealed and can keep out dust, water, rain, snow and others to protect your fuel system,saving you costly engine repairs.
  • ►Safe & Durable - Both dodge ram fuel caps are crafted with anodized billet aluminum which won't be impacted even after long-term exposure.
  • ►Guarantee - We provide 12 months worry-free warranty and lifetime friendly service. If you have any problems please feel free to contact with us.Our service until you are satisfied.

OEM Style Plastic Cap

Amopar plastic fuel capside from the thin green plastic cap, Dodge actually has another style of cap that is more robust and seems like it would do the job of protecting the open fuel filler system.

The part number for this cap: Mopar/Chrysler 82214609.

It does also come with a tether to keep the cap attached and from being lost, a nice feature for those of us that sometimes misplace our fuel caps when refilling our trucks in the morning before coffee.

Dodge Ram Fuel Filler Diesel Cap With Tether Non Locking NEW OEM MOPAR

Dodge Ram Fuel Filler Diesel Cap With Tether Non Locking NEW OEM MOPAR

Check Price
Amazon
as of May 5, 2025 8:50 pm

Features

  • Non-Locking fuel cap for 2014-2016 Ram 1500, 2500, 3500
  • Non-Locking gas cap for capless fuel filler housing
  • Plastic capless cover and tether to prevent dust and debri from entering the fuel system.
  • Diesel only

Conclusion

Hopefully this guide has helped you to find the best options for replacing your truck’s missing fuel cap. If you have any more questions or input about this issue, feel free to drop us a line below in the comments. Thanks for reading!

Filed Under: Guides

How-To: Choose and Use a Diesel Compression Tester

Updated February 22, 2024 by Jeff Hart

Compression tests have always been a go-to for uncovering any issues that an engine might have, and diesel engines are no exception to this rule.

At first glance, it seems like the testing procedure is very similar between gasoline engines and diesels, however testing compression on a diesel does have different requirements, procedures and tooling (namely adapters and high pressure gauges).

The biggest difference you’ll run into when testing a diesel is the pressures that these engines produce. They’re a great deal higher than a regular gasoline combustion engine, which means your test gauge will have to be able to take a greater PSI reading. I recommend going with at least a 1,000 PSI gauge in order to accurately read your cylinder pressures, many regular gauges only go up to 300 PSI which just won’t cut it.

Best Test Gauge for Diesels

This is the best option that I’ve found for a reasonably priced, high quality test gauge that reads up to 1,000 PSI (or 70 bar) which is what you’ll need for a diesel. Keep in mind that this is for the gauge only, you’ll also need to grab the correct adapter kit for your truck, if you keep scrolling I have the most popular adapters listed below.

OTC 5021 Universal Diesel Engine Compression Gauge

OTC 5021 Universal Diesel Engine Compression Gauge

Check Price
Amazon
as of May 2, 2025 3:38 am

Features

  • OTC's Universal Diesel Engine Compression Gauge will work on any diesel engine
  • Tests compression up to 1000 psi and 7000 kPa
  • Features include: check valve, push button compression release, and quick disconnect fitting on hose end
  • Straight and 45 degree hose connectors with quick-connect fittings are included
  • Adapters for specific diesel engine applications not included but are available separately

Diesel Compression Test Kit

If you’re a professional mechanic or just someone that works on more than one type of truck, you’ll probably want to get a test kit that already includes the adapters for all the most popular diesels, instead of buying them piece by piece.

Mityvac MV5535 Digital Diesel Compression Test Kit

Mityvac MV5535 Digital Diesel Compression Test Kit

Check Price
Amazon
as of May 2, 2025 3:38 am

Features

  • It is Highly durable
  • Product type:AUTO ACCESSORY
  • Fit type: Universal
  • Package Weight: 4.4 lbs

7.3L Powerstroke Adapter Kit

On the 7.3 compression testing is best done by removing the glow plugs and inserting the special adapter shown here:

S&G Tool Aid 35250 Diesel Engine Tester Adapter

S&G Tool Aid 35250 Diesel Engine Tester Adapter

Check Price
Amazon
as of May 2, 2025 3:38 am

Features

  • Product Type:Auto Accessory
  • Item Package Dimension:10.16 cm L X 9.144 cm W X 10.16 cm H
  • Country Of Origin: China
  • Item Package Quantity:1

6.0L and 6.4L Powerstroke Adapter Kit

The 6.0 is just like the 7.3 as far as removing the glow plugs to test. You’ll need this adapter for the 6.0:

OTC 6660 Compression Tester Adapter

OTC 6660 Compression Tester Adapter

Check Price
Amazon
as of May 2, 2025 3:38 am

Features

  • OTC Ford Diesel Engine Compression Test Adapter
  • For use with OTC's No. 5021 diesel engine compression gauge
  • This adapter is used to connect the No. 5021 gauge to a glow plug port (after the glow plug has been removed) for performing a compression test
  • Fits 2003-2006 Ford pickups and vans with 6.0L diesel engines
  • Similar to Ford 303-757; high-grade materials ensure quality performance over the lifetime of the tool

5.9 Cummins Adapter Kit

All the years of the 5.9 require the injectors to be pulled in order to perform a compression test. This adapter replaces the removed injector with the 1/8 NPT fitting that works with most gauges.

Lang Tools TU-15-26 Diesel Compression Adapter (Injector)

Lang Tools TU-15-26 Diesel Compression Adapter (Injector)

Check Price
Amazon
as of May 2, 2025 3:38 am

Features

  • Package Dimensions: 3.25 L x 10.5 H x 2 W (inches)
  • Package Weight : 1 pounds
  • Country of Origin : United States
  • Part number: TU-15-26

2005+ 6.6L Duramax Adapter

This adapter threads into the glow plug hole of your Duramax and features a quick release connector to plug into a gauge.

Lang Tools TU-15-38 Diesel Adapter - 6.6L Duramax

Lang Tools TU-15-38 Diesel Adapter - 6.6L Duramax

Check Price
Amazon
as of May 2, 2025 3:38 am

Features

  • Made To Withstand Even The Toughest Jobs
  • Designed With The User In Mind
  • Fit To Match The Needs In The Shop, At Home Or In The Field
  • Proven And Tested For Durability And Function In Real-World Conditions
  • Crafted With The User In Mind Using The High-Quality Materials And World-Class Craftsmanship

Testing Procedure

Depending on which engine you have the test procedure will vary slightly in details, but the overall procedure is similar for most engines:

  • Disable fuel injection
  • Remove all glow plugs to reduce compression resistance
  • Use the correct adapter to thread into the glow plug hole
  • Attach the test gauge to the adapter
  • Verify that ignition is disabled to prevent engine from starting
  • Using a test jumper or remote switch, activate the starter directly
  • Crank the engine for 4-5 revolutions
  • Read and record the final PSI on the gauge
  • Repeat for all cylinders and compare pressures

Compression PSI Specifications/Ranges

I’ve put together the PSI ranges that you should be looking for when doing your compression test. Keep in mind that a lot of these are the specifications for these engines when new or rebuilt. Engines with a lot of miles will naturally have lower PSI because of all the wear and tear.

Generally speaking, you’ll always want to look for the relative compression readings for all of the cylinders comparatively. A huge red flag is more than 75% difference between the individual cylinders.

Ford

  • 7.3  365-475 psi is the acceptable range for the 7.3L Powerstroke.
  • 6.0 375-425 psi is the acceptable range for the 6.0L Powerstroke.
  • 6.4 340-375 psi is the acceptable range for the 6.4L Powerstroke.

Dodge

  • 5.9 6BT The minimum psi spec for the 6BT is 350 psi.

Chevy/GM

  • LB7 Minimum 350 psi.
  • LLY Minimum 350 psi.
  • LBZ Minimum 350 psi.
  • LMM Minimum 350 psi.
  • LML Minimum 350 psi.

Conclusion

We hope this guide has been helpful in answering any questions that you might have had about compression testing your diesel. If you have any questions or concerns, please feel free to post them in the comments section below. Thanks for reading!

Filed Under: Guides

Can an Oil Additive Fix Injector Stiction?

Updated February 22, 2024 by Jeff Hart

In this guide, I wanted to cover an issue that many 6.0 and 7.3 powerstroke owners have run into, Injector stiction. Stiction is unfortunately quite a common problem with the fuel delivery system that these powerstrokes use, and can lead to serious issues with hard starts, rough idling, misfires and terrible overall driveability.

What is stiction?

The 6.0 and 7.3 Powerstrokes use hydraulically actuated electronically controlled unit injector (or HEUI) injectors. Contrary to most modern common rail systems, the HEUI is now an outdated system that was introduced by Caterpillar way back in the 90’s. Instead of using a high pressure injection pump to pressurize the fuel in the injector body (like you’ll find in newer diesels) the HEUI system uses oil that has been pressurized very highly, sent directly into the injectors, to create the required fuel pressure.

Basically, the oil pump pressurizes some of the engine oil, sends it to the HEUI system, which opens or closes a spool valve inside the injector, allowing the oil to push on the intensifier piston. This piston then converts the oil pressure into fuel pressure, and from there the fuel is injected into the cylinder at up to 4000psi.

The problem happens when the spool valve either has oil residue on it and becomes stuck, or when the engine oil becomes foamy to the point where the foam is creating a false injector pressure.

The bad part about this system is that it is affected by low quality fuel and oil, which is all too common and hard to avoid nowadays. Oil residue and foamy oil in the spool valve is the main issue with the HEUI system, and the best way to keep your injectors flowing well is to use an additive to clean them preventatively.

Frequent oil changes are very important for your Powerstroke, remember that the injectors need oil pressure in order to operate and changing and checking your oil is the best way to ensure that the injector system stays operational and in good working condition. The pressure that the HEUI system operates on the oil side can be greater than 3000 psi, which is just terrible for the longevity of your oil, it breaks down the molecules much faster and creates foam.

Another good reason to stay on top of your oil changes.

The best oil additive to cure your diesel’s stiction

There are a few additives out there that claim to fix stiction issues on the powerstroke injectors. Below I’ll cover a few of the most popular ones, and how well they work.

REV-X Engine Oil Treatment Kit Two 4oz Bottles

REV-X Engine Oil Treatment Kit Two 4oz Bottles

Check Price
Amazon
as of May 1, 2025 6:47 am

Features

  • Two 4 fl. oz. bottles of REV X High Performance Oil Additive in our stiction fix retail box. Will treat up to 12 quarts of oil.
  • Quiets engine noise while cleaning harmful deposits, varnish and sludge in all engines. Reduces friction by creating a microscopic friction reduction layer on all treated components to reach areas standard oils can not.
  • Removes stiction, common in HEUI Injectors, without using harmful and dangerous chemical strippers.
  • Extends the service life of all synthetic, semi-synthetic, and mineral based oils providing a reduction of wear of all treated engine components.
  • Greatly improves or eliminates cold start issues in all diesel engines.
I’ve heard the most positive reviews on Rev-x out of all three of these additives. Some people claim that it solved their stiction issues within the first few hundred miles of driving, after adding a couple of these bottles of Rev-x to their truck after an oil change.

Because of the reviews I’ve read about success with this stuff bringing low performing injectors back to life, if a contribution code were to pop up on my truck I would start my troubleshooting with some fresh oil and a couple bottles of this stuff.

AR9100-16oz Powerstroke Cold Starts, an Injector Stiction Solution

AR9100-16oz Powerstroke Cold Starts, an Injector Stiction Solution

Check Price
Amazon
as of May 1, 2025 6:47 am

Features

  • 16oz AR9100 Friction Modifier - treats one Power Stroke
  • Fixes 6.0L and 7.3L Power Stroke cold start injector problems
  • Reduces wear and extends component life
  • Reduces engine noise, vibration and heat
  • For all diesel and gasoline engines, gearboxes, hydraulics, differentials and power steering systems
This friction modifier made by Archoil seems to be pretty much just as good as rev-x, and it costs less (per oz) too, which is why this is the stuff that I use on every oil change with my 6.0 already.

I don’t currently have any symptoms of stiction, like any hard start or rough idle issues with my truck (knock on wood) but I have seemed to notice a bit smoother acceleration since I’ve started incorporating it into my maintenance routine.

Hot Shot's Secret HSS64Z Stiction Eliminator - 64 fl. oz.

Hot Shot's Secret HSS64Z Stiction Eliminator - 64 fl. oz.

Check Price
Amazon
as of May 1, 2025 6:47 am

Features

  • Restore power and performance of your engine back to new while preventing excesssive wear
  • Cleans and lubricates every component in the oil system, including HEUI injectors, turbos and more
  • Reduces wear by up to 62% more than engine oil alone, as verified by third-party testing
  • Restores 9 out of 10 failing HEUI injectors for better performance
  • Works on both gasoline and diesel engines
Hotshot’s secret gets many people saying good things about it as well, a lot of people happy with it fixing their stiction issues.  It’s cost is very cheap compared to the other options, and if I weren’t already happy with what Archoil does for me, I would probably give it a shot.

You really can’t go wrong with trying any of these friction modifiers really, they are all designed to do the same thing basically. If I had an OBD code staring me in the face, I’d start with the Rev-x, as that seems to have the most success with tough cases. For preventative maintenance though, I’d pick one of the other two, just because of cost.

Frequent oil changes

Changing the oil often on a diesel that uses high pressure oil in the fuel injection system is much more important than on a regular gasoline vehicle, and here’s why:

With the very intense pressures of the oil injector system, your oil is subjected to much more wear and tear than in a regular engine because of shear.

Shear is a way to measure the effects that mechanical stress has on your oil.  Being under huge loads like in a diesel injector system reduces the effective viscosity of the oil by a large factor.

This reduction of viscosity means that the oil is much more quickly thinned out in a diesel than a gasoline vehicle, and because of this it ends up being much less effective at lubricating.

In fact, the industry standard test for oil shear by ASTM International (D5275) actually involves running through a high pressure diesel injection system like in a powerstroke, and then comparing the viscosity to fresh oil.

Best oil for preventing stiction

So now that you know how important frequent oil changes are, let’s go over how to choose the best oil to run in your truck to prevent all of the nasty side effects of stiction.

The most important thing to consider when shopping for diesel oil is the additives that they use to protect against shear.

Below is a comparison of what I believe to be the best choice for oil in diesel engines that use a high pressure oil fuel delivery system.

Rotella T6 vs Delo 400LE

Let me start by saying that these two oils are the only kinds that I would ever consider running in my truck. It’s so much more important for these high pressure injector systems to have the right additives in the oil to prolong the inevitable thinning, and regular old wal-mart or whatever oil just won’t cut it.

Rotella T6 is the primary choice here, the additive profile of this oil is top notch, which ensures that it will be a very good choice for diesels that use a HEUI system.

Shell Rotella 550019913-3PK T Triple Protection 15W-40 Heavy Duty Diesel Engine Oil - 1 Gallon (Pack of 3)

Shell Rotella 550019913-3PK T Triple Protection 15W-40 Heavy Duty Diesel Engine Oil - 1 Gallon (Pack of 3)

Check Price
Amazon
as of May 1, 2025 6:47 am

Features

  • Conventional motor oil compatible with most vehicles
  • Motor oil weight: SAE 15W-40
  • Industry-tested for up to 50% less engine wear
  • Enhanced engine cleanliness and viscosity control
  • Designed to control piston deposits in late model engines

That being said, Delo 400LE is also a great choice that is much more cost effective. The only caveat to the Delo oil is that it designed for the newer trucks because it was formulated to meet emissions specs for ’07 and up.

Delo 400 LE/SDE SAE 15W-40 Motor Oil - 1 Gallon Jug

Delo 400 LE/SDE SAE 15W-40 Motor Oil - 1 Gallon Jug

Check Price
Amazon
as of May 1, 2025 6:47 am

Features

  • Fit Type: Universal Fit
  • Enhanced emission control system life
  • Reduced inventory costs
  • Warranty plus protection

Cleaning the spool valve in the injectors

Sometimes, using an additive or changing the oil won’t be enough to clean off the oil residue that is clinging to the spool valves inside your injectors. In this scenario, you’re going to need to either replace the injectors, or pull them and clean the spool valves by hand.

This process is a bit involved, but doable. The best instructions  that I’ve seen for spool valve cleaning are in this video below:

Replacing worn injectors

So, what if you’ve already thrown the book at your Powerstroke by changing the oil, trying one of the additives, and manually cleaning the spool valves in the injectors – but nothing has helped?

More than likely you’re going to have to go with remanufactured injectors like the one below, in order to fix the problem if none of the above has resolved it for you.

OE Ford 4C3Z9E527AA Fuel Injector For 6.0L Ford Diesel (Re-Manufactured)($100.00 Core Deposit Included)(Replaces 1844751C2, 1846692C92, 1845150C92)

OE Ford 4C3Z9E527AA Fuel Injector For 6.0L Ford Diesel (Re-Manufactured)($100.00 Core Deposit Included)(Replaces 1844751C2, 1846692C92, 1845150C92)

Check Price
Amazon
as of May 1, 2025 6:47 am

Stiction Symptoms

Stiction rears its ugly head in the form of misfires on cold starts, rough and uneven idle, and hesitation when accelerating. These symptoms can continue even when the engine has warmed up fully.

Stiction and OBD DTC’s

If your injectors are not operating as they should due to stiction, this can lead to the engine computer throwing out some telltale OBD DTC’s:*

*Acronym Translation: OBD = On Board Diagnostics and DTC = Diagnostic Trouble Codes.

P0263 Valve train or injector cylinder #1 contribution/balance

P0266 Valve train or injector cylinder #2 contribution/balance

P0269 Valve train or injector cylinder #3 contribution/balance

P0272 Valve train or injector cylinder #4 contribution/balance

P0275  Valve train or injector cylinder #5 contribution/balance

P0278 Valve train or Injector cylinder #6 contribution/balance

P0281 Valve train or injector cylinder #7 contribution/balance

P0284 Valve train or injector cylinder #8 contribution/balance

FICM Causing Stiction Symptoms

The spool valves in the injectors operate when they receive a signal from the FICM (fuel injection control module.) It stands to reason, if your FICM is not operating correctly then you will get symptoms of stiction, the spool valves will act similarly to being clogged up if they aren’t receiving the correct signal from the FICM.

Aside from adding a stiction prevention additive, the other first step in troubleshooting a rough running powerstroke, is to test the FICM for the correct voltages. Check out the FICM repair guide for instructions on how to perform that test.

Filed Under: Guides

Transfer Tank Roundup: Best Tank for Your Truck

Updated February 22, 2024 by Jeff Hart

bestinbedtransfertank

Welcome to our fuel tank roundup!

This guide is here to help you figure out what kind of tank your truck needs, whether you need an auxiliary tank for extending your range, a transfer tank for filling your equipment in the field or just a larger capacity factory replacement fuel tank.

First of all, let’s go over what each type of fuel tank does:

Transfer tanks are a remote fueling solution, they are a must-have for your truck if you are running any kind of equipment out in the field, as they keep you from the major inconvenience of having to trailer your equipment to the closest fuel station to fill up.

Auxiliary tanks are a way of extending the range of your truck, by adding another tank that feeds into your truck’s factory tank, you can massively increase fuel capacity.

Higher-capacity tanks are a replacement for your trucks factory tank, these aftermarket tanks take advantage of unused space under the bed of your truck to raise capacity and extend your driving range.

Form Factors

There are a few different styles to choose from when shopping for a transfer tank, some are specifically designed for higher capacity, some for the least size impact (slim rectangle tanks), and others have built-in features like lockable bed toolboxes.

We will go through the different styles and compare the best options from each category, so that you can choose the one that fits your use best.

Best L-Shaped Transfer Tanks

The L-shape of these tanks allows for higher capacity than the slim rectangle tanks, while still allowing you to have a good amount of bed space left for other things like your bed tool box.

The picture above is a good example of how you can use the transfer tank in conjunction with a truck bed toolbox, if you look closely you can see the L-shaped tank is tucked up under the toolbox in this truck bed. This a great option if you already own a truck bed toolbox, simply slide it in under your bed box for maximum fuel capacity and bed space.

RDS MFG INC L Shaped Auxiliary Transfer Fuel Tank - 95 Gallon

RDS MFG INC L Shaped Auxiliary Transfer Fuel Tank - 95 Gallon

Check Price
Amazon
as of May 2, 2025 6:57 am

Features

  • RDS offers a full assortment of tanks in various capacities and dimensions to fit your needs
  • Gasoline auxiliary fueling is allowed, if siphoned from the top of the tank by using an electric fuel pump
  • Product Type - LIQUID FUEL CONTAINER
  • Item Package Quantity - 1

Better Built 29222000 Transfer Tank

Better Built 29222000 Transfer Tank

Check Price
Amazon
as of May 2, 2025 6:57 am

Features

  • Product type :STORAGE BOX
  • Package dimensions :60.0 " L x33.0 " W x25.0 " H
  • country of origin :Mexico
  • package weight :182.0lbs

Best Fuel Tank Toolbox Combo

If you don’t already have a bed toolbox and you’re looking for something that can store your tools and equipment, a fuel tank and tool box combo is probably the best fit for your needs. These boxes combine the versatility of having the fuel on-hand for your equipment, and also the tools that you need to get the job done out in the field.

RDS MFG INC - 72744 Fuel Tank Toolbox Combo - 60-Gallon Capacity

RDS MFG INC - 72744 Fuel Tank Toolbox Combo - 60-Gallon Capacity

Check Price
Amazon
as of May 2, 2025 6:57 am

Features

  • Product Type:Auto Accessory
  • Item Package Dimension:50.8 Centimeters L X 53.34 Centimeters W X 139.7 Centimeters H
  • Country Of Origin: United States
  • Item Package Weight:58.967 Kilograms

RDS MFG INC 72773 Fuel Tank

RDS MFG INC 72773 Fuel Tank

Check Price
Amazon
as of May 2, 2025 6:57 am

Features

  • Aluminum tank and toolbox - no rusting
  • Toolbox built using 0058 ga aluminum
  • Fully welded seams and reinforced lid
  • Universal Fit

Dee Zee DZ92647SB (92 gallon) Black Steel Combo Transfer Tank & Tool Box

Dee Zee DZ92647SB (92 gallon) Black Steel Combo Transfer Tank & Tool Box

Check Price
Amazon
as of May 2, 2025 6:57 am

Features

  • Add Convenient Storage Bolted Onto A Transfer Tank
  • NRT Powder Coat Is A Specially Designed To Increase Corrosion Protection
  • Transfer Tank Features 14-Gauge Steel
  • Volume: 92 Gallon Capacity
  • L-Shape - L: 46.75" x W: 32.75" x H: 25.375"

Best transfer tank pump

Once you have your tank, you’ll need a way to get the fuel out of it and into your equipment or vehicles. The best way to do that is with a 12v electric fuel transfer pump.

Fill-Rite FR4210G Fuel Transfer Pump, Telescoping Suction Pipe, 12' Delivery Hose, Manual Release Nozzle - 12 Volt, 20 GPM

Fill-Rite FR4210G Fuel Transfer Pump, Telescoping Suction Pipe, 12' Delivery Hose, Manual Release Nozzle - 12 Volt, 20 GPM

Check Price
Amazon
as of May 2, 2025 6:57 am

Features

  • DEPENDABLE & DURABLE PUMP: Made with durable cast iron construction to withstand rough operating environments, every 4200 series pump includes a limit lifetime warranty.
  • EASY INSTALLATION: The fuel pump has a removable junction box that rotates 180-degrees for ease of electrical wiring and installation in tight spaces.
  • PROTECTION AGAINST OVERHEATING: Engineered to exceed the industry’s most stringent safety standards, the pump is constructed with thermal overload protection to prevent the motor from overheating during abnormal usage.
  • CONSISTENT HIGH PERFORMANCE: 4200 series Fill-Rite pumps are built with Rotary Vane Technology that maintains a consistent flow performance even as components wear from use.
  • MOBILE APPLICATIONS: Designed for 12V battery powered bung mounted transferring from fuel tanks on trailers or trucks, the 4200 series will pull fuel at tank depths of 8 ft. and discharge fuel up to heights of 37 ft.

Gravity Feed Auxiliary Tank Install

Gravity feeding is the simplest way to have your truck’s tank refilled from your in-bed auxiliary/transfer tank.

Basically all you need to do in order for this to work is to tie a small refill hose from the auxiliary tank right into your main truck tank’s fuel filler hose.

The easiest way to get this done is with an install kit. The kit comes with the fuel filler hose T fitting and a length of hose to connect to your aux tank. It also has a valve to close off the feed when not needed.

Depending on where you tie into the filler hose, you can usually leave the valve on constantly and fill your truck from your transfer tank, which will in turn automatically feed into the main fuel tank.

Best gravity feed install kit:

RDS MFG INC 11029 Diesel Install Kit

RDS MFG INC 11029 Diesel Install Kit

Check Price
Amazon
as of May 2, 2025 6:57 am

Features

  • RDS offers a full assortment of tanks in various capacities and dimensions to fit your needs
  • Gasoline auxiliary fueling is allowed, if siphoned from the top of the tank by using an electric fuel pump
  • Product Type - MOTOR ENGINE FUEL TANK
  • Item Package Quantity - 1

gravity feed tank install diagram

Choosing Tank Materials

Aluminum Vs. Steel Comparison

Figuring out which material is best for your new tank goes beyond how it looks and what is costs. The biggest deciding factor will be how you intend to use the thing. Will you be the operator that is out in the field with his excavation equipment running all day? Or do you only intend to use it for smaller jobs, like refilling a backup generator that only runs during grid downtime? These differences in usage can make or break choosing aluminum over steel, or vice versa.

Option 1 – Aluminum :

Aluminum transfer tanks use a metal that doesn’t rust. Ever. This means that the outside of your tank will always look pristine sitting in the bed of your truck. Rust is bad though, really bad, and for more reasons beyond just how the outside of the tank looks. One of the things that rusted steel does is it flakes apart into tiny little pieces. As you can imagine, tiny little flakes of rust in fuel are terrible for your equipment’s fuel system. No one wants to spend their evenings swapping out fuel filters.

There are a couple different options for exterior tank styles, if you care about that sort of thing. You can usually find aluminum tanks in two main styles, made from stamped sheet.  Usually you can order them in the classic polished silver diamond plate pattern, or with a durable black powdercoat finish.

Best part is, by choosing aluminum you never have to worry again about rust oxidation. These tanks are great for heavy duty use on a daily basis, as part of any job site operation. And as a bonus, they also keep fuels from becoming unusable during those long gaps in fill-up times.

Option 2 – Steel: 

Steel transfer tanks have always looked a bit more rugged to me. They’re built out of thicker metal than aluminum tanks, often resulting in tank walls that use up to 14-gauge steel.

Steel tanks need a coating for the exterior of the tank, for protection from the elements, and to prevent rust. On any good steel tank, you will find that a durable powder coating process is usually used to give the outside of the tanks a longer lasting finish. They can be had usually in black or white as standard colors.

One thing to keep in mind,  while the powder coat will protect the outside of the tank, the interior of a tank made from steel is bare, and needs to be at a constant higher level of fuel, you want to make sure that you have enough in there to cover the walls of the inside of your tank as much as you can, because doing that lubricates the steel and keeps it from rusting into tiny little flakes.

Steel is also cheaper than aluminium, and while you might think that is a great feature, you do want to keep in mind that these work best if you’re the kind of person that would keep their auxiliary tank filled up for the majority of the time. This can’t be any more important, you want to make sure that the inside of your steel tank is always coated with fuel to keep it from rusting.

This is a problem if the tank sits around idle for long periods of time with no movement, but if you drive your truck around alot, it becomes less of a concern, because driving will slosh the fuel around the tank and coat the insides.

So think about how you fit into these usage categories while you look at the options below, it’s an important choice to consider when looking at any kind of fuel tank.

Also to consider: some of the tanks out there will work just fine for on private property or farm use, but there are DOT regulations to consider for fuel tanks that are used for commercial operations.

For more information on DOT rules about fuel tanks: Read the FMCSA regulations

Baffling is another factor that is important to look for in any fuel tank, these internal structures keep the fuel from sloshing around during transportation and are a need for DOT certification.

auxiliarytankbaffles

Conclusion

We sincerely hope this roundup has helped you to narrow down your options for adding a tank to your truck. As always, if there are any questions or comments that you have, feel free to leave them in the comments below. Thanks for reading!

Filed Under: Guides

FICM OBD Codes and Repair Guide

Updated February 22, 2024 by Jeff Hart

Is your 6.0 Powerstroke having trouble starting? Have you been getting terrible fuel economy?

Do you have a check engine light with any of the following OBD codes?

  • P0261
  • P0264
  • P0267
  • P0270
  • P0273
  • P0276
  • P0279
  • P0282

(Injector circuit low voltage)

If so, you might be experiencing FICM failure. This is a common issue for these trucks, and I think most 6.0’s will have problems with the FICM at some point in their lifetime.

What the heck is this FICM thing you might ask?

  • Ford 6.0 Powerstroke FICM 4C3Z-12B599-ABRM

    Ford 6.0 Powerstroke FICM 4C3Z-12B599-ABRM

    Check Price
    Amazon
    as of May 7, 2025 2:23 pm

    Features

    • $250 refund with return of your original module
    • Upgraded control board over Ford & International OEM replacements - 5 YEAR WARRANTY!
    • We will contact you for your VIN to ensure proper programming
    • Remanufactured in the USA

The Fuel Injection Control Module – is an electronic module in charge of deciding the amount of fuel to deliver to each of the cylinders. It does this by relaying voltage to close and open each cylinder’s fuel injector, to deliver the pressurized fuel with the correct timing.

As your truck racks up mileage, the FICM starts having trouble in doing its job correctly. A big issue with these is with the solder on the output circuit board. Over time, the solder fails on the connections for the components of the board, and as a result the output voltages drop below the required parameters.

This causes the injectors to not open and close when they should, leaving you with a truck that is impossible or very difficult to start, even more so a problem in cold weather. Also, depending on how shot your module is, you may have already noticed a real drop in your fuel economy,

Damage to the FICM is mostly caused when your batteries or alternator are too weak to do their jobs adequately. These 6.0’s come with only an 110 amp alternator, the same kind that Ford uses on some of their passenger cars, not very robust at all for the powerstroke needs.

This is a bad thing because when cranking your powerstroke, the glow plugs and just the required starting electronics can draw about 230 amps. You can easily see the issue of having a weak electrical system there. A good practice is to periodically check your charging system, especially the batteries.

If your truck isn’t your daily driver, you can extend the life of those expensive batteries by using a desulphating smart battery charger. If it is already too late for your old batteries, it might be time to upgrade to AGM batteries.

An upgraded alternator can also make a big difference in the life on the onboard electronics. A higher amperage alternator for the 6.0 powerstroke is a very good upgrade for your truck’s electrical system.

Testing for a failed FICM

In order to verify if you are in need of a FICM repair or replacement, you will want to check the output voltage on the module itself.

You will need a multimeter and an assistant to perform this test:

  1. Remove the coolant reservoir with a 10mm ratchet and place aside or remove
  2. Locate the FICM and the pinout cover
  3. Use a T20 Torx bit to remove the two cover fasteners
  4. Set your multimeter to DC volts and attach the negative lead to the battery negative terminal.
  5. Touch the positive lead to the pin on the FICM that is closest to the driver’s side. Don’t led your lead touch the case!
  6. Have your assistant turn the key on, but not to start
  7. Read the voltage, it should be right at 48v and no higher than 49v or lower than 47v.

How to fix your FICM

There are a couple of different ways to go about fixing your defective fuel injection control module, the best option is simply repairing the part that has failed in most people’s broken FICM. By far, the most module issues that people experience come from a failed power supply circuit board.

The good news is that the FICM power supply board is a cheap and easy fix.

This fix works for the 6.0 control module found in late 04-07 Super Duty pickups, and the Econoline vans, which also used the same module up until the 2010 model year I believe.

The actual repair is pretty simple, once you’ve gotten your FICM out of the truck, you just have to open the case and remove the Torx (T10 and T20 bits are required) screws to get at the circuit board.

A new power supply board can easily be found on Amazon:

  • Dorman 904-229 Fuel Injection Control Module

    Dorman 904-229 Fuel Injection Control Module

    Check Price
    Amazon
    as of May 7, 2025 2:23 pm

    Features

    • Direct replacement - this FICM inverter board replaces the original board on certain Ford and Navistar vehicles to restore operation when the original unit fails from excessive heat and vibration
    • Cost-saving solution - when FICMs fail, it's often only the power board, not the controller board and housing that make up the entire module; save money by just replacing broken board
    • No programming required - if you replace the entire module, you need to reinitialize it using professional tools, but not if you replace only the inverter board with this repair kit
    • Improved design - since the factory board fails from excessive heat and vibration, this unit features additional securing compound to help prevent it from failing the same way again in the future
    • Ensure fit - to make sure this part fits your exact vehicle, input your make, model and trim level into the garage tool

The best part is that by just replacing this board, the repair is a fraction of the cost of replacing the entire module as a whole part.

The below video is the best walk through that I have seen for this repair, as you can see it really isn’t that terrible of a job.

FICM cross reference numbers:
Ford OEM part numbers#: 3C3Z12B599AARM, 4C3Z12B599AARM, 4C3Z12B599ABRM, 4C3Z12B599BARM
Navistar part numbers: 1845117C2, 1845117C6, 5010121R94

Filed Under: Guides

How-To: Choose The Best Batteries for Your Truck

Updated February 22, 2024 by Jeff Hart

What could possibly be worse than the Monday morning commute to work?

How about when you go to start your truck one cold January morning in preparation for your drive and all you get from the truck is endless cranking or a dull click from the starter?

Of course, batteries are pushed the hardest in the winter and in our freezing conditions it was really no surprise that the fail so often in these conditions.

Unfortunately, I speak from experience, as this had actually happened to me. I hadn’t driven the truck at all that weekend, so my batteries were just done with life after sitting inactive that long in the cold.

I learned a couple of important lessons that day, number 1 being that jumper cables do you no good at all if no one is around to give you a jump, number 2 being that when 5 year rated lead acid batteries haven’t been replaced in 7 years, they’re pretty darn prone to fail at any point.

What is the best truck battery?

If you shop around in stores and online these days, you’ll find that there are more than a dozen different main battery brands. What you probably didn’t know (and neither did I) but there’s really only a few of the main manufacturers that are actually producing the batteries for all of these different brands.

In case you were wondering, the breakdown of the manufacturers of the different mainstream brands are as follows:

Johnson Controls makes Duralast (for Autozone,)  EverStart, AutoCraft (Advanced Auto’s brand) as well as Diehard and Interstate.

Exide is another of the big guys, they put out batteries under their own Exide brand, as well as under Orbital, Bosch and Marathon.

EnerSys Energy Products is the company behind the Odyssey brand batteries.

East Penn Manufacturing is well known for producing the Deka brand automotive batteries.

Which size batteries to buy?

The comparisons below focus mainly on which of the group 65 batteries are the best option, as this is the size I needed for my 6.0 powerstroke. Of course, if you are in the market for a new truck battery, you would want verify that your truck uses this size group also before buying one (a lot of diesels do).

For other trucks, check the following:

  • 2000-2005 Dodge Ram w/Cummins 5.9L: Group 65   Requires 2 Batteries
  • 2006-2017 Dodge Ram w/Cummins 6.7L: Group 94R    Requires 2 Batteries
  • 2003-2007 Ford Powerstroke 6.0L: Group 65    Requires 2 Batteries
  • 2008-2014 Ford Powerstroke 6.4L: Group 65    Requires 2 Batteries
  • 2015-2017 Ford Powerstroke 6.7L: Group 65    Requires 2 Batteries    
  • 2008-2010 Chevy Duramax LMM: Group 48    Requires 2 Batteries
  • 2011-2016 Chevy Duramax LML: Group 48     Requires 2 Batteries

Take note:  If your truck uses two batteries, it is best to have a matching set, as it will extend the overall life of your truck’s electrical system. Always replace in pairs for a dual battery setup.

Battery Comparison

  • Odyssey 65-PC1750T Automotive and LTV Battery

Odyssey has been making the best batteries around for quite awhile now, and while they are definitely not the cheapest option, they are virtually unbeatable in terms of quality.  This monster in particular provides 950 CCA (cold cranking amps) which would be enough power to start the most stubborn of trucks, even in extreme weather conditions. The sealed AGM (absorbed glass mat) design of the battery will hold up to almost all conditions that you can throw its way, from vibration to very cold and very hot temperatures no problem.

Odyssey 65-PC1750T Automotive and LTV Battery

Odyssey 65-PC1750T Automotive and LTV Battery

Check Price
Amazon
as of May 1, 2025 4:55 am

Features

  • Cold Crank Amp (CCA)- 950
  • Better warranty: Limited 3 and 4 year full replacement warranty - not pro rata
  • Includes SAE Automotive terminals
  • Mounting flexibility: Non-spill able design, vibration resistance- design protects against high impact shock and mechanical vibration
  • Extreme temperature tolerant- Operating temperatures from -40 degree Celsius (-40 degree Fahrenheit) to 45 degree Celsius (113 degree Fahrenheit).

  • Deka Intimidator Extended Life AGM Battery 9A65

Skip the inflation of buying a name brand, and go right to the manufacturer with these Deka batteries. These are made by East Penn Manufacturing, who have been behind the scenes of many of the most popular battery brands for decades. This model has the AGM technology along with 860 CCA at 32° F to start you up reliably, even in colder temperatures. The advantages of the AGM construction are vibration resistance (good for off-road) and longevity. The Deka brand in particular is an exceptionally good value because of the elimination of the middle man who slaps an auto parts or battery store brand on and marks up the final cost for no good reason – as they’re still an East Penn made battery.

Deka Intimidator Extended Life AGM Battery 9A65

Deka Intimidator Extended Life AGM Battery 9A65

Check Price
Ebay.com
as of May 1, 2025 4:55 am

Battery Features:

20 amp hour rate: 75
Battery End Type: Top Post
BCI Group Size: 65
CA at 32 degrees F: 860
CCA at 0 degrees F: 750
Country of Origin (Primary): US

  • XS Power D6500 XS Series 12V 3,900 Amp AGM

The XS Power D6500 is actually an AGM battery, which means it has the superior glass mat inside. It’s also made in the USA, which is good to see these days. Apparently these XS Power batteries are used in a lot of custom audio cars, so that’s a good indicator of massive capacity which translates well for diesels.

XS Power D6500 XS Series 12V 3,900 Amp AGM High Output Battery with M6 Terminal Bolt

XS Power D6500 XS Series 12V 3,900 Amp AGM High Output Battery with M6 Terminal Bolt

Check Price
Amazon
as of May 1, 2025 4:55 am

Features

  • : The 12V XS Power AGM battery features sealed, maintenance-free AGM tech, offering leak resistance and long lifespan. Perfect for powering many Ford, Lincoln and Mercury models and more high-energy accessories like audio systems or other electronics in all weather conditions.
  • : This 12V Deep Cycle Small AGM battery offers 1100 cranking amps (CA) and 968 cold cranking amps (CCA) for reliable engine starts in extreme weather. It powers car audio systems, electronics, and high-demand devices, keeping your ride smooth in all temperatures.
  • : This 12V powersports battery features a sealed, leak-proof AGM design, is maintenance-free, and includes M6 terminal hardware for easy installation. Perfect for custom setups, with a 3-year warranty for long-lasting performance.
  • - : This 12V AGM deep cycle battery(Group 65) offers 3800 max amps, 86 amp-hours (AH) capacity, and 174 minutes of reserve power. It operates seamlessly Secondary 3000W/4,000W Range and its compact size (11.8" L x 6.80" H x 7.20" W) and lightweight design (53.81 lbs) ensure versatility. Backed by a 3-year warranty.
  • : Weighing only 53.81 lbs, the XS Power D6500 is designed for effortless portability and installation. Its compact size makes it perfect for powering aftermarket accessories like car audio systems, power inverters, or LED lights, providing high power without the bulk of traditional batteries.

  •  Delphi AGM Group 65 Battery

This Delphi has surprisingly good pricing, but also with a trusted name brand behind it and AGM technology. Many folks swear by this battery, it is a popular option with a lot of diesel guys. Boasting high cycling capabilities and being very charge receptive, as well as 100% leak proof, it’s a really good choice for most daily drivers.

Delphi BU9065 MaxStart AGM Premium Automotive Battery, Group Size 65

Delphi BU9065 MaxStart AGM Premium Automotive Battery, Group Size 65

Check Price
Amazon
as of May 1, 2025 4:55 am

Features

  • Extended cold cranking amps delivery means more power for today's demanding electronics
  • Group 65 battery with 750 CCA (cold cranking amps) and 150 R. C. (reverse capacity)
  • 20x the vibration resistance of conventional batteries
  • Superior vibration resistance, optimized component compression , and fortified posts, straps and welds
  • Fit type: Vehicle Specific

Hard start issues caused by low batteries

On a diesel truck, the amperage of your batteries is of even more importance than on a gas powered vehicle. When you turn your key and engage the ecm, glow plugs, ficm, fuel pump and starter, a huge draw is put onto the batteries, and they really need to be healthy for everything to work as it should.

I’ve seen trucks before that sounded really healthy and fine when cranking over, but just seemed to not want to start. I later found that this was because the batteries were not supplying enough amperage for all of the ancillaries to do their jobs.

With this in mind, if your truck starts having issues with starting, the first thing to test would be the batteries, if they are older than their rated lifespan.

Testing Batteries

If you’re not sure if your batteries are actually bad or not, the best way to find out is by hooking up a battery tester and seeing what the readout and load test have to say about how healthy your batteries and charging system are.

You can always do a quick multi meter check for the minimum 12v when the truck is off and at least 13v running, however a battery with a bad cell can still put out 12v but not be able to provide enough amperage.

The best way to take all of the guesswork out of the equation is with a battery testing tool such as this one:

FOXWELL Battery Tester 12V Automotive Battery Analyzer Health/Faults Detector BT100 Pro

FOXWELL Battery Tester 12V Automotive Battery Analyzer Health/Faults Detector BT100 Pro

Check Price
Amazon
as of May 1, 2025 4:55 am

Features

  • Classic Edition, More Reliable: With over 13 years of brand expertise and 9 years of continuous upgrades, Foxwell prioritizes customer trust. BT100 Battery Tester offers lab-grade precision via advanced conductance technology and a smart chip (99.6% accuracy) at a DIY-friendly price, delivering rapid results and 5 professional recommendations (replace/charge/monitor) to prevent unnecessary swaps—saving over $120 annually. Tip: For 12V lead-acid batteries only: AGM, EFB, GEL and Regular-Flooded.
  • Easy to Read & Use: This 12v battery tester features large backlit LCD screen ensures clear visibility in both bright daylight and low-light conditions. With a simple 3-step process requiring no technical skills—connect the clamps to the battery terminals, select the battery type , and input the CCA/AH values—battery tester 12v automotive instantly analyzes SOH (State of Health), SOC (State of Charge), CCA , and internal resistance, delivering professional-grade diagnostics. Critical Note: Insufficient CCA can leave your engine dead in freezing weather, while abnormal internal resistance in a single battery cell may doom the entire pack to failure.
  • Not Only Accurate, But Knows You Better: Foxwell BT100 battery tester delivers precise measurements with its upgraded intelligent chip, enhanced copper clamps (strong conductivity), and automatic temperature compensation. Ideal for 12V battery vehicles, it helps detect battery issues so you can replace it on time during the warranty period. Whether it's the hot summer or the cold winter, use the BT100 to test your battery before heading out, saving you time and money Tip: Suitable for 12V ATV, MOTORCYCLE, SUV, LIGHT TRUCKS, BOAT
  • Help You Make the Right Decision:Tired of vague ‘Good/Charge/Bad’ guesses? Automotive battery tester cuts the uncertainty with 5 expert-level diagnostic results—factoring in undercharging, poor cable connections, and hidden flaws—to slash false alerts by 70% and save you from costly misjudgments. Whether you’re tackling daily errands or facing critical moments, this tool arms you with confidence. Pro Tip: When testing in-vehicle, disconnect all accessory loads, ensure the key is OFF, and close doors to eliminate interference.
  • Track Battery Performance & Eliminate Guesswork: This 12v auto battery tester features robust data logging, allowing users to easily access the last test results to track changes in battery performance and detect potential issues early. Foxwell battery analyzer tester also supports nine languages, eliminating any concerns about language barriers while reading the results

FICM Damage caused by bad batteries

Another big thing to watch out for, especially with the 6.0 powerstroke, is bad batteries taking out your FICM (Fuel Injection Control Module). A defective FICM can easily keep your truck from running correctly, or even at all, often throwing codes for all of the injectors, which is a dead giveaway.

It’s a good idea to always periodically check you batteries to make sure that they are not putting excessive load onto the charging system, which is what ends up damaging the FICM.

Read more about how to trouble shoot and repair your control module in our FICM repair guide.

Conclusion

Hopefully this guide has been informative and has given you a better idea of which batteries you need for your truck. As always, if you have any questions or concerns feel free to leave us a comment below! Thanks for reading!

Filed Under: Guides

Best Upgrades For The 6.0L Powerstroke

Updated February 26, 2025 by Jeff Hart

6.0powerstrokeupgrades

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

SCT Livewire Vision for Ford Powerstroke 7.3, 6.0, 6.4, 6.7 5015P

Check Price
Ebay.com
as of May 3, 2025 10:40 pm

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

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

Check Price
Amazon
as of May 3, 2025 10:40 pm

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

MBRP 4" Straight Pipe Exhaust For 2003-2007 Ford F-250 F-350 6.0L Powerstroke

Check Price
Ebay.us
as of May 3, 2025 10:40 pm


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

BANKS 42155 Ram-Air Intake System, 2003-2007 6.0L Ford

Check Price
Amazon
as of May 3, 2025 10:40 pm

Features

Part NumberM143787833


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

Garrett Powermax Turbocharger for 04.5-07 Powerstroke 6.0L Turbo

Check Price
Amazon
as of May 3, 2025 10:40 pm

Features

BrandGarrett
Catalog Number ListCatalog Number List Element: BDZW772441-5002S
EAN0681430477541
EAN ListEAN List Element: 0681430477541
Item DimensionsHeight: 0; Length: 0; Weight: 0; Width: 0
LabelGarrett
ManufacturerGarrett
Manufacturer Parts Warranty DescriptionParts
MPN772441-5002S
Number Of Items1
Package DimensionsHeight: 1050; Length: 1400; Weight: 4185; Width: 1140
Package Quantity1
Part Number772441-5002S
Product GroupAutomotive Parts and Accessories
Product Type NameAUTO_PART
PublisherGarrett
StudioGarrett
TitleGarrett Powermax Turbocharger for 04.5-07 Powerstroke 6.0L Turbo
UPC681430477541
UPC ListUPC 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

Upgraded EGR Cooler & Oil Cooler Kit For Ford F-250 350 6.0L Powerstroke Diesel Turbo

Check Price
Ebay.com
as of May 3, 2025 10:40 pm


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.

Genuine Ford 6E7Z-9A332-B Fuel Supply Tube

Genuine Ford 6E7Z-9A332-B Fuel Supply Tube

Check Price
Amazon
as of May 3, 2025 10:40 pm

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

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

Check Price
Amazon
as of May 3, 2025 10:40 pm

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)

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)

Check Price
Amazon
as of May 3, 2025 10:40 pm

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

Mishimoto MMICP-F2D-03BK Intercooler Pipe Kit Compatible With Ford 6.0 Powerstroke 2003-2007 Black

Check Price
Amazon
as of May 3, 2025 10:40 pm

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

Silver Aluminum Degas Bottle/Coolant Y-Pipe/Gold Antifreeze 03-07 6.0L Powerstroke

Check Price
Ebay.com
as of May 3, 2025 10:40 pm

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!

Filed Under: Guides

6.0powerstrokeupgrades

Best Upgrades For The 6.0L Powerstroke

March 27, 2016 By Jeff Hart 8 Comments

Have you been searching to find the most popular … [Read More...]

Best Upgrades for 7.3L Power Stroke

Best Upgrades for the 7.3L Power Stroke

February 5, 2020 By Jeff Hart Leave a Comment

The 7.3L Powerstroke is commonly regarded as … [Read More...]

How-To: Choose and Use a Diesel Compression Tester

February 1, 2017 By Jeff Hart 3 Comments

Compression tests have always been a go-to for … [Read More...]

How-To: Choose The Best Batteries for Your Truck

July 8, 2016 By Jeff Hart 1 Comment

What could possibly be worse than the Monday … [Read More...]

How To Fix The Missing Fuel Cap on Rams

May 8, 2017 By Jeff Hart 1 Comment

Starting in 2013 and continuing still to this day, … [Read More...]

FICM OBD Codes and Repair Guide

July 19, 2016 By Jeff Hart 1 Comment

Is your 6.0 Powerstroke having trouble starting? … [Read More...]

Can an Oil Additive Fix Injector Stiction?

December 6, 2016 By Jeff Hart 4 Comments

In this guide, I wanted to cover an issue that … [Read More...]

tailgate dampener assist

How-To: Add a tailgate assist to your truck

July 17, 2017 By Jeff Hart Leave a Comment

Have you ever had your hands full while trying to … [Read More...]

Transfer Tank Roundup: Best Tank for Your Truck

September 13, 2016 By Jeff Hart 2 Comments

Welcome to our fuel tank roundup! This guide is … [Read More...]

Site Search & Info

[email protected]

[Lets Encrypt]
DMCA.com Protection Status

Subscribe!

Enter your email address to recieve all of our newest tips and guides, directly to your inbox!

  • Facebook
  • Twitter
  • LinkedIn
Note: DieselPowerUp.com is intended purely for entertainment purposes. We do not assume liability for how any information on DieselPowerUp.com is used. For site and affiliate partner disclosures, please read our Privacy Policy

© 2025 · DieselPowerUp.com