The 6.0 turbo rebuild is an engine that’s been in production since 1997 and has seen many changes over the years. The most common issues with this motor are related to head gaskets, variable cam timing, exhaust gas recirculation and more recently the high pressure fuel pump (HPFP). This article will go through some of these problems so you can be better informed when making a decision about your next 6.0 Turbo Rebuild project!

Head Gaskets: The 6.0G powerstroke is notorious for head gasket issues, with a reported failure rate of 67% according to FHWA 2006 report (pg 110). This can be caused by the cooling system not reaching adequate temperature or coolant boiling over due to excessive heat and pressure in the engine.

Older model years are more prone than newer ones because their cylinder heads were cast from aluminum rather than iron which lead to increased warping. However, on all models overheating will cause leakage past the head bolts when they loosen up due to metal creep – this could happen as early as 100K miles! It’s important that you perform regular preventative maintenance like keeping your coolant topped off at all times or having your cooling system flushed and refilled every 25K miles to compensate for this.

Older 6.0s also have a tendency to rust where the exhaust manifold enters the downpipe, causing leaks that could lead to engine flooding with coolant if caught too late! I recommend inspecting it at least once per year for any corrosion buildup inside.

The 6.0 is notorious for head gasket issues with a 67% failure rate according to FHWA 2006 report (pg 110). This can be caused by either not reaching adequate temperature in the cooling system or boiling over due excessive heat and pressure in the engine on older models which are prone because their cylinder heads were cast from aluminum rather than iron leading them to increased warping when subjected to heat and pressure.

If your 6.0 is overheating, it’s likely an issue with the head gasket or a lack of coolant in the system due to a leak somewhere that needs repair ASAP!

The 6.0 also has issues with leaking oil from between the cylinder heads into the cylinders themselves, which will cause engine failure if left unchecked for long periods of time because this can lead to serious corrosion on piston rings and other parts within the motor itself (pg 111). If you’re experiencing excessive burning smells or black smoke out of exhaust pipes then you could be looking at big problems as well so have someone inspect those immediately.”

“Many people are unaware that their 2005-2007 Ford F250/F350 6.0L Powerstroke diesel truck is equipped with a turbocharger, which helps the engine produce more power by using exhaust gases to push air into the combustion chambers.”

“The 6.0 diesel was designed and built in collaboration between Ford and International Truck Division (Navistar) for use as an alternative fuel vehicle that could meet stricter emissions standards from U.S. regulations without sacrificing performance or reliability.”

“…Since these engines are often used for work trucks, there is also a higher demand on them when it comes to how long they can stay on before needing service…This means you’ll be paying attention not only to what your gas mileage looks like but also at how many miles per time period you’re getting out of your 6.0 diesel.”

“Turbochargers are one of the most complex and expensive components in a vehicle, which is why it’s important to take care of them as much as you can so they last as long as possible.”

“…If you’re looking for more information about how turbochargers work with these engines or what symptoms may cause them to fail, check out Ford Parts & Accessories official page on this topic: “Engine Turbocharger Basics”


We hope this article helped you better understand and identify the common problems that come with a 6.0 turbo rebuild. If your engine is suffering from any of these issues, we can help! Give us a call to learn more about our experience in fixing high pressure fuel pump (HPFP) related failure or for general information on our services including an affordable 6.0 Turbo Rebuild project today!