Ford 6.0L PowerStroke Problems Solved – Eisenhart Diesel

With the laundry list of issues that we identified in Part One, we have developed a simple set of fixes to solve your 6.0L Powerstroke problems!  This is the same 6.0L Powerstoke Solution we have done for so many other diesel owners in PA, MD, NJ and VA. We are experts at solving and fixing 6.0L Powerstroke problems and this  has made us the best shop for 6.0L Powerstoke repairs in Central PA. Lets get into the crux of the issues and their solutions.

 

1. 6.0L Oil Cooler

An upgraded Oil Cooler will keep your 6.0L Powerstroke on the road.

An upgraded Oil Cooler for the 6.0L Powerstroke is a must.

The oil used in the 6.0L Power Stroke HEUI injection systems is the hardest working oil in the world. As you can imagine, engine oil that’s pressurized as much as 3,600 psi gets really hot, and not being able to adequately control the oil’s temperature can lead to a host of engine problems. When the minuscule coolant passages within the oil cooler’s fluid-to-fluid heat exchanger plug up, and they always do, the coolant is no longer able to properly cool the oil. The Eisenhart Diesel fix for the system is 2 fold, we replace the oil cooler unit with a much better designed unit which will not clog and 100% of the 6.0L PowerStrokes we fix get a bypass coolant filter to eliminate this engine grenade.

 

 

 

2.The EGR Cooler and the Domino Effect

power-stroke-6-0L-oil-flowThe illustration to the right details how coolant moves through the 6.0L Power Stroke engine. Notice that after coolant leaves the oil cooler, it flows to the exhaust gas recirculation (EGR) cooler. The EGR cooler uses engine coolant to remove heat from a portion of the spent exhaust gases as they’re directed back to the vehicle’s intake to help reduce the creation of NOx (nitrogen oxide) emissions. The EGR system is not a nessessary system, and actually hinders the longevity of the engine, so removal of the system is the best solution.

 

 

3. Inside the EGR Cooler: Two Common Problems

2004-ford-f350-bulletproof-power-stroke+egr-system
If you own a Ford Super Duty pickup with the 6.0L engine, chances are you have experienced some level of EGR cooler failure. Ford has released several technical service bulletins to its dealer network in an attempt to resolve these problems. The problem is that none of them address the root cause, and though the dealership may replace faulty EGR coolers under warranty, the issues will continue to persist. When you take a look inside of some of these EGR coolers as we have, it’s easy to understand their shortcomings.

Failed 6.0L EGR

 

1.This is an example of a failed EGR cooler that caused a catastrophic engine failure. Notice the cracked coolant passageway (arrow). This unit failed because of a clogged oil cooler and excessive exhaust gas temperatures. This type of failure is typically caused by running an aggressive tuner or chip on a 6.0L with coolant flow issues. You see, the EGR cooler is the next place engine coolant goes after leaving the factory engine oil cooler. When the coolant side of the oil cooler is restricted, the EGR cooler cannot cool hot exhaust gases effectively. The EGR cooler was never designed to handle extreme heat and therefore develops a rupture or crack. When this type of failure occurs, coolant will mix with exhaust gases inside the EGR cooler.

This will lead to what Eisenhart Diesel calls Cylinder Soup:

Head Gasket Replacement

A leaking EGR may cause the head gasket to blow.

cloggedEGRCooler2.This photo shows the other type of EGR failure that Eisenhart Diesel encounters regularly. Exhaust gases deposit gunk on the cooling fins inside the EGR cooler. This causes restriction within the unit. This restriction cuts down on the EGR’s effectiveness, allowing higher exhaust gas temperatures to reach the intake manifold. Generally, this type of failure can be traced back to a clogged engine oil cooler. As the coolant side of the oil cooler becomes restricted, less heat is scavenged from the engine oil. This results in higher coolant temperatures and a lower volume of coolant exiting the oil cooler. As the restricted and hot coolant reaches the EGR cooler, the hot exhaust gases “flash-boil” the coolant in the adjacent channels of the EGR cooler. This failure usually results in loss of coolant from the coolant reservoir. This condition typically leads to a rupture failure of inside the EGR cooler, and eventually results in blown head gaskets.

 

 

4. Head Gasket Failure -

A leaking EGR frequently results in a “blown head gasket” and actually damages the studs which clamp the head to the block. Doing any EGR or Oil cooler as a repair or as preventative maintance requires the replacement of the head gaskets and the installation of upgraded head studs which will lead to a longer engine life for your truck.
Solutions:

Now we get to the best part, how Eisenhart Diesel can address all of these problems.

1. We will replace the Oil Cooler with a more robust unit which will not clog as easily as the stock 6.0L PowerStroke Oil Cooler. We also install a bypass coolant filter to ensure that the new oil cooler will not have a chance to get clogged with any contamination flowing around within the coolant. We can also at this time upgrade your oil pump if you are planning on modifing your 6.0L Powerstoke!

2.  We can either remove the EGR system or replace it with an upgraded unit degisned which is much more robust and less likely to clog. The use that the truck sees will be the determining factor in which method is used to alleviate the issue. If replacing the EGR Cooler we will check and either clean or replace your EGR Valve.

3. Replace the Head Gaskets and upgrade the studs to ARP Head Studs.

4. CLEAN IT! The leaking coolant that most 6.0L PowerStroke engines have, causes rust and damage thoughout the engine. We meticulously clean out any and all of the contaminants so that you do not end up with more problems down the road!

The 6.0L Powerstroke Problems are all caused from a few root causes. Fixing the 6.0L Powerstroke Problems is not impossible, you just need a qualified shop familiar with the engine. Eisenhart Diesel are experts at dealing with the 6.0L Powerstoke, so give us a call today to get your truck running its best.