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2004 Ford E-350 Super Duty
Reliability tier: verified - see /disclosure/
Engine: 6.0L (Power Stroke, 6.0L)
head dowel: 18mm (E-Series engines built before the 2006-01 dowel change). Late-2004 build ('2004.5') engines received the 2005-spec HPOP with the STC snap-to-connect fitting (fm-6-0-stc-fitting); a small early-2004 build window kept the round-style EGR cooler, the 90mm-impeller water pump and the 7-pin FICM - see part fitment notes.
Applicable failure modes (11)
- Cooling system degradation / no coolant filtration
- Degas bottle / coolant reservoir crack, or failed cap
- EGR cooler failure
- FICM (Fuel Injection Control Module) failure
- Marginal regulated fuel pressure (blue spring)
- Head gasket failure / cylinder head lift
- Fuel injector stiction / failure
- IPR (Injection Pressure Regulator) valve failure
- Engine oil cooler clogging / failure
- VGT turbocharger sticking
- Water pump failure
Applicable parts (22)
- Coolant Filter Element (replacement, SCA-free for HOAT)
- 6.0L Power Stroke Coolant Filtration Kit (spin-on)
- Ford Specification Gold HOAT Coolant (6.0L Power Stroke)
- 6.0L Power Stroke Degas Bottle Pressure Cap
- 6.0L Power Stroke EGR Cooler, upgraded (Bullet Proof Diesel)
- 6.0L Power Stroke EGR Cooler Install Kit (gaskets, o-rings, hardware)
- 6.0L Power Stroke EGR Cooler, OEM-style replacement
- 6.0L Power Stroke EGR Valve
- 6.0L Power Stroke FICM (Fuel Injection Control Module), complete
- 6.0L Power Stroke FICM Power Supply (rebuild board, higher output)
- 6.0L Power Stroke Fuel Filter Set (HFCM lower + secondary/upper)
- 6.0L Power Stroke Fuel Pressure Regulator "Blue Spring" Upgrade Kit
- 6.0L Power Stroke Cylinder Head Bolt Kit (OEM torque-to-yield)
- 6.0L Power Stroke Head Gasket Set, 18mm dowel
- 6.0L Power Stroke Cylinder Head Stud Kit (ARP 2000)
- 6.0L Power Stroke ICP Sensor (Injection Control Pressure)
- 6.0L Power Stroke IPR Valve (Injection Pressure Regulator) with screen & o-rings
- 6.0L Power Stroke Oil Cooler Gasket / O-Ring Kit
- 6.0L Power Stroke Engine Oil Cooler (valley, oil-to-coolant)
- 6.0L Power Stroke Thermostat
- 6.0L Power Stroke VGT Turbocharger (reman / upgraded)
- 6.0L Power Stroke Water Pump
Platform recipes (5)
- The classic emissions-legal 6.0 bulletproof at stock power, using OEM-style coolers
- The full emissions-legal bulletproof: upgraded (round-tube) EGR cooler + external/relocated oil cooler that removes the OEM clog point entirely, ARP head studs with new gaskets matched to dowel size, complete cooling refresh, FICM upgrade, and full high-pressure-oil system refresh
- A modest, streetable power bump (tune + supporting mods) done the right way - on a bulletproofed, studded bottom-of-the-cascade truck
- Preventive baseline for a stock, healthy 6.0 with no current failures
- For a stock-power 6.0 used to tow, with no full bulletproof budget yet