6.0 Power Stroke Maintenance Guide

6.0 Power Stroke Maintenance Schedule

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

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

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

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

Normal Service Intervals

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

Severe/Heavy Duty Service Intervals

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

6.0 Power Stroke Oils, Lubricants, & Fluids

Engine Oil Viscosity Chart

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

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

Oil & Fluid Specifications

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

Oil & Fluid Capacities

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

6.0 Power Stroke Service Parts List

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