Applicable Models:
2003 - 2007 Ford F-250, F-350, F-450, F-550 Super Duty
2003 - 2005 Ford Excursion
2004 - 2010 Ford Econoline E-350
2003 - 2008 Ford F-650, F-750 medium duty trucks
Applicable Engine(s):
6.0L Power Stroke diesel V-8
Application Transmissions:
Ford 5R110W TorqShift five speed automatic
ZF S6-750 six speed manual
Applicable Drivetrain:
2 wheel drive and 4 wheel drive models
6.0 Power Stroke Maintenance Schedule
The maintenance schedule for "normal" driving conditions assumes the vehicle is driven unladen in ideal traffic conditions with minimal engine idling and constant road speeds. A vehicle will fall under the "severe" or "heavy duty" service category if it meets any of the following criteria:
• Vehicle is idled frequently and/or excessively (generally defined as 10 minutes or more idling within a 1 hour window)
• Vehicle makes frequent short trips in which the engine often shutdown repeatedly before reaching full operating temperature
• Vehicle is driven off-road or in conditions that require the 4 wheel drive to be engaged
• Vehicle experiences light towing/hauling in excess of 1,000 miles between oil change intervals
• Vehicle tows and/or hauls medium to heavy loads
• Engine is run on biodiesel or biodiesel blends (any concentration)
As a general rule-of-thumb, most owners of a heavy duty pickup truck or van will fall under the severe/heavy duty service category, requiring an alternative maintenance schedule calling for more frequent service procedures. If in doubt about which service category your vehicle falls under, always adhere to the more stringent severe/heavy duty service intervals.
Many service intervals are provided in distance driven OR a period of time; service should be performed when either of these two conditions are met, whichever comes first.
Normal Service Intervals
Service Procedure | Service Interval(s) |
Replace engine oil & oil filter | Every 7,500 miles/6 months |
Replace fuel filter | Every 15,000 miles |
Replace engine air filter | Monitor air filter minder (mounted to air filter housing), replace as necessary |
Flush/service engine cooling system | 100,000 miles/5 years initially Every 45,000 miles/36 months thereafter |
Replace automatic transmission fluid & filter | Every 30,000 miles |
Replace manual transmission fluid | Every 60,000 miles |
Replace transfer case fluid | Every 150,000 miles [1] |
Replace front differential fluid (4x4) | Every 100,000 miles [1] |
Replace rear differential fluid | Every 100,000 miles [1] |
[1] - Replace oil/fluid as soon as possible if component is submerged in water; water intrusion highly probable.
Severe/Heavy Duty Service Intervals
Service Procedure | Service Interval(s) |
Replace engine oil & oil filter | Every 5,000 miles/6 months |
Replace fuel filter | Every 15,000 miles when using conventional diesel fuel Every 7,500 miles when using biodiesel blends exceeding B5 (5% biodiesel) |
Replace engine air filter | Monitor air filter minder (mounted to air filter housing), replace as necessary |
Flush/service engine cooling system | 100,000 miles/5 years initially Every 45,000 miles/36 months thereafter |
Replace automatic transmission fluid & filter | Every 30,000 miles |
Replace manual transmission fluid | Every 60,000 miles |
Replace transfer case fluid | Every 60,000 miles [2] |
Replace front differential fluid (4x4) | Every 30,000 miles [2] |
Replace rear differential fluid | Every 30,000 miles [2] |
[2] - Replace oil/fluid as soon as possible if component is submerged in water; water intrusion highly probable.
6.0 Power Stroke Oils, Lubricants, & Fluids
Engine Oil Viscosity Chart

An engine oil viscosity grade should be selected based on the expected ambient temperature range in which the vehicle is to be operated. Due to the 6.0L Power Stroke's EGR system, an engine oil that meets API CI-4/CH-4 specifications is required. Note that certain viscosity grades are listed as "acceptable" within a temperature range while others are listed as "preferred". When possible, select an engine oil viscosity that is listed as preferred within the expected temperature range.
For most applications, SAE 15W-40 engine oil is recommended. We highly recommend a high quality synthetic motor oil due to its resilience against degradation and oxidation in engines employing an HEUI injection system. Synthetic motor oils will provide improved wear protection under the strenuous oil pressures these systems endure.
Oil & Fluid Specifications
Fluid Type | Oil/Fluid Specification | Remarks | |
Engine oil | SAE 15W-40 preferred in ambient temperatures > 30° F Recommend Amsoil Max Duty Signature Series 15W-40 diesel oil |
[3] | |
SAE 10W-30 preferred in ambient temperatures between -10 to 30° F Recommend Amsoil Max Duty Signature Series 10W-30 diesel oil |
|||
SAE 5W-30 acceptable in ambient temperatures < 30° F | |||
SAE 0W-30 acceptable in ambient temperatures < 0° F | |||
Engine Oil API Category | CI-4/CH-4 or equivalent | --- | |
Engine coolant | Motorcraft VC-7-B Gold concentrated engine coolant mixed 50/50 with distilled water Motorcraft VC-7DIL-B Gold prediluted engine coolant (do NOT add water) |
--- | |
Automatic transmission fluid | Motorcraft MERCON SP ATF (XT-6-QSP) | --- | |
Manual transmission fluid | Motorcraft MERCON V ATF (XT-5-QMC) Recommend Amsoil Signature Series Synthetic ATF |
--- | |
Transfer case fluid | Motorcraft MERCON LV ATF (XT-10-QLVC) Recommend Amsoil FE Synthetic ATF as a high quality, full synthetic alternative |
[4] | |
Front differential gear oil | SAE 80W-90 gear oil or SAE 90W hypoid gear oil Recommend Amsoil Severe Gear 80W-90 synthetic gear oil |
--- | |
Rear differential gear oil | Sterling 10.50 | SAE 75W-140 full synthetic gear oil Recommend Amsoil Severe Gear 75W-140 synthetic gear oil |
[5] |
Dana 80 | SAE 75W-90 full synthetic gear oil Recommend Amsoil Severe Gear 75W-90 synthetic gear oil |
||
Dana S135 | SAE 80W-90 gear oil Recommend Amsoil Severe Gear 80W-90 synthetic gear oil |
||
Dana S110/S130 | SAE 75W-140 full synthetic gear oil Recommend Amsoil Severe Gear 75W-140 synthetic gear oil |
||
Limited slip additive | Motorcraft XL-3 friction modifier | ||
Brake fluid | Motorcraft PM-1 DOT 3 brake fluid Recommend Amsoil DOT 3 synthetic brake fluid |
--- | |
Clutch hydraulic fluid | |||
Power steering fluid | Motorcraft MERCON V ATF (XT-5-QMC) | --- |
[3] - Refer to viscosity chart for complete viscosity grade application details; be mindful of the terms "preferred" and "acceptable". When possible, select a viscosity grade that is preferred within the expected ambient temperature range in which the vehicle is being operated.
[4] - MERCON LV replaces prior Motorcraft XL-12 transfer case fluid specification.
[5] - Limited slip differentials may require a friction modifier to prevent chatter; use Motorcraft XL-3. Sterling 10.50 used in single rear wheel applications only. Dana 80, S110, S130, and S135 rear differentials used in dual rear wheel applications only.
Oil & Fluid Capacities
Fluid Type | Oil/Fluid Capacity | Remarks | |
Engine oil | 15.0 U.S. quarts | [6] | |
Engine coolant | 6.875 gallons | --- | |
Automatic transmission fluid | 17.5 U.S. quarts | [7] | |
Manual transmission fluid | 5.8 U.S. quarts | [8] | |
Transfer case fluid | 2.0 U.S. quarts | [8] | |
Front differential gear oil | 3.0 U.S. quarts | [8] | |
Rear differential gear oil | Sterling 10.50 | 3.45 U.S. quarts | [8],[9] |
Dana 80 | 4.25 U.S. quarts | ||
Dana S135 | 12.25 U.S. quarts | ||
Dana S110/S130 | 8.4 U.S. quarts | ||
Brake fluid | N/A; fill to reservoir marker | --- | |
Clutch hydraulic fluid | N/A; fill to reservoir marker/line | --- | |
Power steering fluid | N/A; fill to correct dipstick level | --- |
[6] - Engine oil refill capacity with lube oil filter change
[7] - Total transmission fluid capacity listed; actual service refill capacity significantly less, add fluid through dipstick tube until appropriate dipstick level indicator range has been reached
[8] - Fill component until oil has reached the lower level of the fill plug hole; fill plug height is the appropriate lubricant level indicator. When checking fluid level, oil should be no less than 1/4 inch below the fill plug opening. Always fill and check fluid level with vehicle parked on level ground.
[9] - If friction modifier/additive is required for limited slip differential, add before filling with gear oil. Dana 80, S110, S130, and S135 rear differentials used in dual rear wheel applications only.
6.0 Power Stroke Service Parts List
Part Description | Part Number(s) | |
Engine air filter | Motorcraft FA-1778 (Ford 4C3Z-9601-AA) | |
Engine oil filter | Motorcraft FL-2016 (Ford 3C3Z-6731-AA) | |
Oil filter housing cap/lid | Motorcraft EC-781 (Ford 3C3Z-6766-CA) | |
Engine oil fill cap | Motorcraft EC-743 (Ford F3AZ-6766-B) | |
Oil pan drain plug | Ford 8C3Z-6730-A | |
Fuel filter set | Motorcraft FD-4616 (Ford 3C3Z-9N184-CA, includes engine & chassis filters, o-rings) | |
Fuel filter housing cap/lid | Ford 3C3Z-9G270-AA | |
EGR valve o-ring set | Ford 3C3Z-9P455-AB | |
Serpentine belt | Motorcraft JK81267A (Ford 3C3Z-8620-DB, single alternator) | |
Glow plug [10] | 2003 - early 2004 |
Motorcraft ZD-12 (Ford 3C3Z-12A342-AA), see warning [10] |
2004 - 2007 | Motorcraft ZD-13 (Ford 4C3Z-12A342-AA, set of 8) | |
Thermostat | Motorcraft RT-1169 (Ford 3C3Z-8575-AA) | |
Thermostat housing gasket | Ford 3C3Z-8255-AA | |
Radiator overflow/degas cap | Ford 9C3Z-8101-B | |
Upper radiator hose | Motorcraft KM4783 (Ford 3C3Z-8260-AG) | |
Lower radiator hose | Motorcraft LM4784 (Ford 3C3Z-8286-AJ) | |
Camshaft position sensor (CPS) | Ford 8C3Z-12K073-A | |
Crankshaft position sensor (CKP) | Ford 3C3Z-6C315-AA | |
Exhaust backpressure sensor (EBP) | 2003 - 2004 [11] | Motorcraft DPFE-3 (Ford 4C3Z-9J460-A) |
2005 - 2007 | Ford 5C3Z-9J460-B | |
Injector control pressure sensor (ICP) | 2003 - early 2004 [12] | Ford 3C3Z-9F838-EA |
2004 - 2007 | Ford 4C3Z-9F838-A | |
ICP sensor pigtail | Ford 5C3Z-12224-A REID TEKK RT-150701 |
|
Injection pressure regulator (IPR) | 2003 - early 2004 | Ford 3C3Z-9C968-AA |
2004 - 2007 | Ford 5C3Z-9C968-CA | |
Automatic transmission filter (TorqShift 5R110W, 5 spd) |
Primary filter | Motorcraft FT-144 (Ford 3C3Z-7A098-AA) (internal transmission filter) |
Auxiliary filter | Motorcraft FT-145 (Ford 3C3Z-7B155-BA) (external, frame mounted filter) |
[10] - 6.0 Power Stroke pistons were redesigned for the 2004 model year, requiring a shorter glow plug. Early glow plugs CANNOT be used in later engines as they WILL contact the piston and cause severe engine damage. Engines built after 9/29/2003 received the new piston design and are considered late 2004 engines. Note that early 2004 model year vehicles received 2003 model year engines, so you must refer to the engine build date, not the vehicle build date.
[11] - 2003 and early 2004 model year engine calibrations use an inferred exhaust backpressure reading; the sensor is not used by the PCM and should not require replacement.
[12] - The ICP sensor on 2003 and early 2004 model year trucks is located behind the turbocharger next to the IRP valve. Late 2004 and later engines have the ICP sensor located through the passenger side valve cover. The ICP sensors are physically different for early and late model engines.