Highest Mileage 6.0 Power Stroke – How Much Can It Go?

We love discussing the longevity of the legendary engines because every owner will have their own stories and opinions. We rely on common sense and analytics, so we never agree on those individual opinions and always present our own view that takes this certain engine in general and makes an average presumption of the durability.

Key features and my opinion about the engine

• Production years:2003-2009
• Average lifespan of 6.0L Power Stroke:320,000-350,000 miles
• Fuel supply type:direct injection
• Power range:325 hp
• Fuel efficiency:bad
• Engine block material:cast-iron
• Engine reliability score:low
• The most common problems:EGR cooler and oil cooler problems, fuel pump issues, head gasket problems, oil pump failing.

What's interesting in the 6.0 Power Stroke engine construction?

We've already told you about the specific construction features of the 6.0 Power Stroke, so today we'll only touch on some things that are important within our today's article. It means you will have the opportunity to predict the highest mileage of this engine after you know something about it.

For example, you may know that Ford used the Power Stroke 6-liter engine in its super-duty trucks, Econoline vans, and also in the Excursion SUV. This means the engine was relied on as a really durable unit.

But here's what you may not know:

• the 6.0 Power Stroke is a diesel engine with 6 liters of displacement and 325 horsepower of power;
• it offers wonderful torque of 570 lb-ft with opportunities to get even more after tuning;
• a lot of Power Stroke engines of this generation experienced problems and some of these troubles were really awful;
• but not a lot of problems could change the longevity - you should invest money in it, but it will go for hundreds of thousands of miles;
• fuel injectors are quite simple in construction but they are not as durable as you may want them to be;
• the construction is OHV which is reliable and simple, the engine has 4 valves per cylinder and 8 cylinders;
• a single VGT turbocharger is as simple as a rock but it's quite durable and mainly lives very long;
• the engine construction is thought to be relatively simple and good to use, especially if you want a durable engine for a long time.

It's not really common for Americans to purchase a vehicle with a diesel engine. But the legendary Power Stroke family is famous for a lot of wonderful technical decisions. The engine construction is great and it can survive the harsh conditions and even bad maintenance. But if you want to use your 6.0 Power Stroke for a really long time, you will have to obey some rules.

These engines were introduced in 2003 to replace the gigantic 7.3 Power Stroke diesel. In 2009, the last Econoline equipped with the Power Stroke 6-liter engine was made. After that, the 6.4 Power Stroke appeared to rival the new competitors.

What are the fatal problems of the 6.0 Power Stroke diesel?

At first, we should say that these engines are pretty good and durable, but during your experience with them, you will get a lot of minor problems. These troubles don't usually affect longevity and other important features, but they may spoil your mood significantly.

The 6.0 Power Stroke engine is not very up-to-date compared with all those modern low-displacement diesel engines packed with electronics and new technologies. These are just old standard engines without a lot of high-performance units. When Ford was engineering the 6.0 Power Stroke, this company paid attention to longevity and reliability.

But still, the 6-liter Power Stroke can surprise you with such problems:

1. Fuel injection trouble. Yes, the injectors in the Power Stroke will get on your nerves and sometimes even make you crazy. They are not the most durable part of this engine, although they can live about 150,000 miles without major problems. Repair or replacement will solve the trouble.
2. HPOP. A high-pressure oil pump will fail at 100,000 miles approximately. Well, you can still repair it and let it work for another 50K miles. But after that, you'll need to replace it. The worst thing is that it costs a couple of thousand dollars to replace this unit.
3. The oil cooler and EGR cooler will fail regularly. Coolant leaks and oil leaks will be there with you for all the years that you will own a truck or a van powered by the 6.0 Power Stroke. Don't worry much, EGR and oil cooler maintenance will not be extremely expensive.
4. Head gasket issues. Early engine (2003-2005) had this bad issue with head gaskets. Two heads made the problem two times more possible in the case with these engines. Well, it's not very hard and expensive to replace the gasket, but the most important thing is to locate the problem on time.
5. Turbocharger death. If we are talking about the highest-mileage 6.0 Power Stroke engine, we are pretty sure, it will have its turbocharger replaced at least once or maybe even a couple of times. The turbo is simple in construction and not extremely expensive, but it still can give you some problems.

Well, it's hard to find some severe problems that can really affect longevity. But you need to know that the engine will start burning some oil after 200,000 miles and it will keep doing that until you replace the piston rings and valve seals.

Also, excessive oil consumption may result in poor efficiency of the engine, loss of compression, low oil level, poor oiling, and also quick engine wear.

We don't recommend driving the car equipped with this Power Stroke engine once it has some problems. You should stop the vehicle, locate the problem and maybe even call a tow truck because it will be cheaper than replacing the engine.

What's the maximum durability of the 6.0 Power Stroke?

We believe that the highest mileage of the 6.0 Power Stroke is about 1,000,000 miles. So, it's a million-mile engine that can surprise you with its efficiency and quality. But we should say that after 300,000 miles, this engine starts taking some money from your pocket.

When you are considering the longevity and durability of some engines, you should think about the economically wise mileage. Basically, you can drive any engine up to 1 million miles, but you will need to replace literally everything, starting with the gaskets and finishing with the block and heads. If it's OK for you, then yes, the 6.0 Power Stroke can go a million miles.

We believe that the optimal mileage for this engine to go to the scrapyard is about 300,000 miles of 350,000 miles. Because after it gets this mileage, the engine will not be reliable anymore. And it won't be cheap to maintain.

What should you do to drive the Power Stroke 6.0 at least 1 million miles?

Let's try to predict what can make this engine last more than a million miles. You need to know that even obeying these rules will not guarantee anything.

Here are some ideas:

• maintain the engine regularly and change oil and filters more often than said by the manufacturer;
• only use high-quality oil which is recommended for the 6.0 Power Stroke;
• every year, ask a mechanic to provide a full diagnostics to find any minor problems and then solve them;
• only buy OEM parts when you need to repair this engine;
• avoid revving up this engine too much, big-displacement diesel units hate this;
• change valve seals and piston rings every 200,000 miles to refresh the engine;
• use good fuel because otherwise, the fuel injection will fail too often.

Also, bear in mind that a cold climate will also kill this engine faster. You should never risk the engine and use it in harsh conditions. For example, avoid towing more weight than the towing capacity allows you to.

Be careful with cold driving. After you start your 6.0 Power Stroke, give it at least one or two minutes to idle and warm up a little before you start driving. Although this is not a very eco-friendly habit, it can save your engine from cylinder block damage.

Final words

We know that a lot of people prefer the 6.0 Power Stroke when it comes to big diesel engines. But you should know that these units have both advantages and problems. Yes, it can go up to 800,000 miles or even to 1 million miles, but not every Power Stroke engine will do this. In most cases, these engines are still good and can drive last up to 350,000 miles provided they get good maintenance and regular oil change.