Close

2003-2007 6.0L Fluid Capacities

Fluid Capacity

  • Fluid Type
    Application
    Fluid Capacity
    Service Interval
    Fluid Spec
    Notes
  • Fluid Type
    Engine Oil
    Application
    6.0L Eng
    Fluid Capacity
    2003 14.6 L , 2004 - 2006 14.2 L, 2007 14.9 L
    Service Interval
    7,500 miles/6 months under normal operating conditions 5,000 miles/6 months under severe duty conditions
    Fluid Spec
    SAE 15W-40 Super Duty Motor Oil or SAE 10W-30 Super Duty Motor Oil
    Notes

    Recommend:
    Blue Diamond PAO Synthetic 5W-40
    Blue Diamond PAO Synthetic 10W-30
    Green Diamond Synthetic 5W-40
    Green Diamond Synthetic 10W-30

    Above 20°F ……….15W-40
    Above -0°F ……….10W-30
    Above -20°F ……….5W-40

  • Fluid Type
    Fuel Tank
    Application
    F250 Super Duty,F350 Super Duty,6.75 FT. Bed Len
    Fluid Capacity
    29.00 GALS.
    Service Interval
    Fluid Spec
    Ultra-Low Sulfur Diesel
    Notes

    Recommend: Use Diesel Extreme every 6,000 miles and Everyday Diesel Treatment with every fill up. For additional lubricity, LX4 Lubricity Extreme may be used. In freezing temperatures, switch from Everyday Diesel Treatment to Diesel Winter Anti-Gel for protection against fuel gelling.

  • Fluid Type
    Fuel Tank
    Application
    F250 Super Duty,F350 Super Duty,8 FT. Bed Len
    Fluid Capacity
    38.00 GALS.
    Service Interval
    Fluid Spec
    Ultra-Low Sulfur Diesel
    Notes

    Recommend: Use Diesel Extreme every 6,000 miles and Everyday Diesel Treatment with every fill up. For additional lubricity, LX4 Lubricity Extreme may be used. In freezing temperatures, switch from Everyday Diesel Treatment to Diesel Winter Anti-Gel for protection against fuel gelling.

  • Fluid Type
    Automatic Transmission Fluid
    Application
    F250 Super Duty, F350 Super Duty, Trans Mfr CD 5R110W TorqShift & 4R100
    Fluid Capacity
    TorqShift 7.1 L, 4R100 6.1 L, 5R110W 7.5 QTS.
    Service Interval
    30,000 miles
    Fluid Spec
    MOTORCRAFT Automatic Transmission Fluid MERCON SP
    Notes

    MERCON, MERCON V and MERCON SP are not interchangeable. DO NOT mix MERCON, MERCON V and MERCON SP. Indicates only approximate dry-fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should be set by the indication on the dipstick’s normal operating range. Includes Remote Filter Element Change.

  • Fluid Type
    Manual Transmission Fluid
    Application
    S6-650 (6-SPD)
    Fluid Capacity
    5.5 L
    Service Interval
    60,000 miles
    Fluid Spec
  • Fluid Type
    Brake Fluid
    Application
    Fluid Capacity
    N/A
    Service Interval
    Fluid Spec
    MOTORCRAFT High Performance DOT 3 Motor Vehicle Brake Fluid
    Notes

    Fill to line on reservoir.

  • Fluid Type
    Differential Gear Oil
    Application
    F250 Super Duty,F350 Super Duty Front,Dana 60 Axle
    Fluid Capacity
    2.7 L
    Service Interval
    100,000 miles under normal operating conditions 30,000 miles under severe duty conditions
    Fluid Spec
    Notes

    BLUE DIAMOND SEVERE DUTY GEAR OIL 75W90 S9

    FORD design rear axles contain a sythetic lubricant that does not required changing unless the axle has been submerged in water. Dana rear axles also contain a synthetic lubricant but do required a change. Add 8 oz. of Additive Friction Modifier XL-3 or equivalent meeting FORD Specification: (EST-M2C118-A) for a complete refill of Limited Slip Axles.

  • Fluid Type
    Differential Gear Oil
    Application
    F350 Super Duty Rear,Dana 80
    Fluid Capacity
    4 L
    Service Interval
    100,000 miles under normal operating conditions 30,000 miles under severe duty conditions
    Fluid Spec
    SAE 75W-90 Synthetic Rear Axle Gear Oil
    Notes

    Recommended: BLUE DIAMOND SEVERE DUTY GEAR OIL 75W-90 S9

    FORD design rear axles contain a sythetic lubricant that does not required changing unless the axle has been submerged in water. Dana rear axles also contain a synthetic lubricant but do required a change. Add 8 oz. of Additive Friction Modifier XL-3 or equivalent meeting FORD Specification: (EST-M2C118-A) for a complete refill of Limited Slip Axles.

  • Fluid Type
    Engine Coolant
    Application
    6.0L Eng
    Fluid Capacity
    27.50 QTS.
    Service Interval
    Fluid Spec
    FORD Premium Gold Engine Coolant
    Notes

    Includes heater and 5 qts. in coolant recovery tank.

  • Fluid Type
    Power Steering Fluid
    Application
    Fluid Capacity
    Service Interval
    Fluid Spec
    MOTORCRAFT Automatic Transmission Fluid MERCON V
    Notes

    BLUE DIAMOND ATF+4/DEXRON III/MERCON V (+4/D3/M5)

    Fill between “max” and “min” lines on reservoir.

  • Fluid Type
    Transfer Case Fluid
    Application
    4WD
    Fluid Capacity
    1.9 L
    Service Interval
    150,000 miles under normal operating conditions 60,000 miles under severe duty conditions
    Fluid Spec
    Notes

    Service refill capacity is determined by filling the Transfer Case to the bottom of the filler hole with the vehicle on a level surface.

  • Fluid Type
    Windshield Washer Fluid
    Application
    Fluid Capacity
    4.25 QTS.
    Service Interval
    Fluid Spec
    MOTORCRAFT Premium Windshield Washer Concentrate Fluid
    Notes

    Follow the Manufacturer’s Instructions for the mixture ratio.

6.0 Powerstroke Service Schedule

6.0 Powerstroke Maintenance Guide and Service Schedule

The design of the Ford 6.0L Powerstroke engine gives it higher maintenance requirements than some other motors. Many of the innovations implemented in the 6.0L Powerstroke when it was introduced in 2003 led to new issues before they were refined in later models. Repairs on these trucks usually require raising the cab, which can result in a high mechanic bill, so it’s key to focus on preventative maintenance and regular upkeep to prevent your 6.0 from developing any major issues. 

The professionals at Hot Shot’s Secret have put together this guide to walk you through regular maintenance and the ideal service schedule to keep your diesel truck running at its best. 

 

Service Schedule

The Ford 6.0L Powerstroke requires owners to go above and beyond the requirements of the manual for a service schedule. To maximize the engine’s life span, you’ll want to change your oil and filter every 5,000 miles and change the coolant every 20,000 miles. The cooling and exhaust gas recirculation (EGR) systems built into the 6.0 Powerstroke are more prone to breakdowns and premature part failures than other systems, so it’s vital to pay extra attention to these elements.

Your Powerstroke service schedule should look something like this: 

  • Change oil: 5,000 miles
  • Change oil filter: 5,000 miles
  • Change fuel filter: 10,000 miles
  • Replace air filter: As needed
  • Flush cooling system: 40,000 miles
  • Replace auto transmission fluid: 30,000 miles
  • Replace manual transmission fluid: 60,000 miles
  • Change external transmission filter: 30,000 miles
  • Change internal transmission filter: 30,000 miles
  • Replace transfer case fluid: 150,000 miles
  • Replace rear differential fluid: 100,000 miles
  • Replace front differential fluid: 100,000 miles

Oil and Fluid Capacity For 6.0 Powerstroke

Before you begin selecting the perfect oil or fluid to optimize the performance of your Powerstroke engine, you need to confirm how much it requires to deliver its best performance. Although the numbers here are a helpful estimate, it’s important to remember that the final authority on your 6.0’s oil capacity and current needs is the dipstick or measuring device built into your truck. 

  • Engine oil: 15 quarts 
  • Auto transmission fluid: 7.5 quarts
  • Manual transmission fluid: 5.8 quarts
  • Transfer case: 2 quarts
  • Coolant: 27.5 quarts
  • Front differential fluid: 3 quarts

The amount of rear differential fluid required will vary based on your model. 

Powerstroke Maintenance Checklist

6.0 Powerstroke Maintenance Checklist

With a diesel engine, regular preventive maintenance helps your truck go much further than only paying attention to it when something breaks. Following this 6.0 checklist and evaluating your truck’s critical areas will help you extend the engine’s useful life and prevent many common problems associated with this model.

Every time you change your truck’s oil, be sure to take a look at these other points: 

  • Check your air filter
  • Inspect boots and hoses for leaks
  • Monitor fluid levels
  • Check tire pressure
  • Inspect suspension and steering components
  • Perform battery checks

Common 6.0 Powerstroke Problems

6 Common 6.0 Problems

The 6.0 was included in Ford Super Duty trucks from 2003 to 2007. Although intended for heavy-duty applications, this model is also known for experiencing frequent issues due to design flaws. The following are six common problems with the 6.0L Powerstroke that you can watch for in the hopes of preventing a major breakdown: 

1. Head gasket failures

The 6.0L Powerstroke comes with torque to yield (TTY) head studs. The issue with these head studs is that they cannot handle aftermarket performance modifications — even adding a tuner to your setup can cause pressure to build beyond the capacity of the cylinder head and lead to head gasket failure. Replacing these with aftermarket head studs can allow you to add performance modifications. 

2. FICM failure

The Fuel Injector Control Module (FICM) is a common source of issues with the 6.0L Powerstroke engine. This part controls oil flow to the fuel injector by applying an electrical voltage to the solenoids. When engine heat and vibration begin to build, however, the FICM may overheat and fail.

You can identify a faulty FICM with a scan tool and a look at the parameter identifiers (PID). The issue occurs because the FICM is located on the side valve cover of the engine, meaning that cold starts expose it to excessive voltage and may damage the capacitors necessary for its proper function. 

3. Oil cooler issues

A large number of the problems commonly present in the 6.0L Powerstroke engine originate from the oil cooler. These engines tend to be temperamental and often require more extreme oil cooling than other trucks. To try to compensate, Ford placed a liquid-on-liquid engine oil cooler within the engine.

Over time, particulates like dirt and sand tend to clog the cooler and cause it to malfunction. Because the oil temperature factors heavily into engine function, it’s therefore vital to inspect and consider replacing your oil cooler when you detect any significant spikes in temperature.

4. Turbocharger issues

The variable geometry turbo (VGT) helps the engine by reducing spool times, but it’s also highly vulnerable to soot buildup over time. When the vanes begin to stick open, it can cause slow throttle response, raise turbo spool times and potentially cause a complete failure of the turbocharger if the oil overheats. 

5. EGR cooler failure

Another common clogging issue with the 6.0L Powerstroke engine is the EGR cooler. When particulates block the airflow of the EGR cooler, the temperature begins to rise, eventually causing the engine to die. As a side effect, the head gasket will also eventually fail if the issue isn’t addressed. A common symptom is white exhaust coming from the tailpipe as a result of the EGR cooler allowing an internal coolant leak. 

6. HPOP Failure

The high-pressure oil pump (HPOP) pressurizes engine oil for compression in the injectors. On the 6.0 Powerstroke, these units have a tendency to fail and cause leaks in the engine seals. To monitor its condition, it’s critical that you periodically inspect the HPOP, taking care to examine the HPOP screen located underneath the oil cooler. 

DIY Service Video Series

How to Grease Front End & Driveshaft Zerks on a 2003-2007 Ford F-250/F-350 6.0L Powerstroke.

Greasing front end and driveshaft zerks on a 2004 Ford F-250 with a 6.0L Powerstroke.
Model Years: 2003, 2004, 2005, 2006, 2007
Ford Super Duty F-250 and F-350

The Hot Shot’s Secret “How ...
to” series is provided for informational purposes only. It is intended to provide general guidance only. Tools, techniques, best practices, products and regulations are continually changing, We assume no responsibility for the completeness, reliability nor accuracy of the information in this video. It is the responsibility of the viewer to ensure compliance with all applicable laws and safety regulations. Hot Shot’s Secret disclaims liability for any omissions, errors, material performance or the outcome of any project. Any action you take upon the information in this video is strictly at your own risk and we will not be liable for any losses and damages in connection the use of this video. If you have a question regarding any element of a project, please consult a professional rather than exclusively relying on this video.[+] Show More

Improve Your 6.0 Powerstroke’s Performance With Hot Shot’s Secret

The diesel professionals at Hot Shot’s Secret understand the unique challenges and advantages you face with a Ford Powerstroke 6.0L engine. That’s why we’ve developed specialized diesel formulas designed to maximize your vehicle’s performance. We offer oil additives, fuel additives, bypass filters, engine oils, transmission fluids and transmission additives

 Ready to make a purchase or have questions? Browse our selection of diesel additives now or give us a call with your questions at 800-341-6516. 


The contents of HotShotsSecret.com, such as text, graphics, images, and other material contained on the Diagnose Your Diesel section are for informational purposes only. Always seek the advice of your mechanic or other qualified professional with any questions you may have regarding your vehicle’s condition.

TALK TO AN EXPERT

800-341-6516