Best Powerstroke 6.0L Upgrades - DieselPowerUp (2023)

Best Powerstroke 6.0L Upgrades - DieselPowerUp (1)

In this guide, we'll look at a few ways to start you on your way to getting more out of your 6.0 Powerstroke.

We'll start with the basics. An EGR delete kit, air intake and exhaust are great ways to increase your truck's power and reliability, as modifying these systems allows your truck to breathe much easier and run much more efficiently.

We've compiled a short list of the parts you'll need for these upgrades for the 6.0L engine in ’03-07 Forddiesel trucks. If you have a newer truck, check out our guides on it6.4 litersiPowerful shots 6.7L.

  • The best receiver for the Powerstroke 6.0L

The one key to getting the most horsepower, torque and fuel economy out of the 6.0 is a good tuner.

Sometimes called a programmer or chip, the right receiver will allow you to change the fuel map, erase codes and certain sensors, display gauges and virtual gauges to monitor your truck, and more. It is a vital part of any construction.

There are a lot of options when it comes to 6.0 receivers, but only a few give you maximum tuning right out of the box. Our favorite is Livewire, mainly for its on-screen tracking/counter capabilities.

Best Powerstroke 6.0L Upgrades - DieselPowerUp (2)

SCT Livewire TS+ Programming Receiver for Ford Powerstroke 7.3, 6.0, 6.4, 6.7 5015P

Check the price
Best Powerstroke 6.0L Upgrades - DieselPowerUp (3)

from May 30, 2023, 2:52 p.m

Manufacturer's description
4" color touch screen
The Livewire TS+ has a 4" color touch screen with a built-in ambient light sensor for automatic brightness adjustment day and night.

Switch on the go*
Switch on the go*
Change power levels on the fly while driving. *Switch On-The-Fly is only available for selected vehicles.

Contains up to 10 custom ringtones
Contains up to 10 custom ringtones
The Livewire TS+ comes pre-installed with Dyno Proven performance tuning files and contains up to 10 custom tuning files for maximum tuning flexibility.

  • Blue Spring Fuel Pressure Upgrade Kit

The Blue Spring mod is a very popular performance and reliability upgrade for 6.0 and for good reason. This simple trick will increase fuel pressure by about 10-15psi, making your truck run much quieter while also reducing pressure on the injectors.

For your money it is one of the cheapest and best fuel models you can get in these trucks. Especially needed if you intend to add other boost mods to your truck.

Best Powerstroke 6.0L Upgrades - DieselPowerUp (4)

Nadogradnja kompleta 6.0 Blue Spring - Komplet regulatora goriva - Ford Blue Spring Kit 6.0 Powerstroke F250, F350, F450, F550 2003, 2004, 2005, 2006, 2007 - 3C3Z-9T517-AG

from May 28, 2023, 11:25 a.m


  • Increase fuel pressure for better performance. This upgrade will increase fuel pressure by 10-15psi on the powerstoke 6.0. It also extends the life of the fuel injectors.
  • Easy to set up. The Blue 6.0 Spring Kit includes all gaskets, seals, bolts, spring and regulator housing required for installation. This fuel regulator kit includes a detailed installation video (link included in package) with step-by-step instructions for upgrading the blue spring.
  • Compatible with Ford 6.0L Powerstroke trucks - F250, F350, F450, F550 model years 2003, 2004, 2005, 2006, 2007
  • Equivalent to factory part 3C3Z-9T517-AG Ideal for stock trucks or modified trucks. The 6.0 Blue Spring kit is a common upgrade as it extends the life of the injectors, improves driveability and allows for smoother power delivery.
  • Complete kit with everything you need to install on your 6.0 Powerstroke: Blue Spring Upgrade, 4 Rubber O-Rings, 3 Port Gaskets, 4 Bolts, Fuel Pressure Regulator Housing
(Video) Top 10 6.0 Powerstroke Mods
  • Turbo rear exhaust

Very simply, the best turbo rear exhaust system for a 6.0 powerstroke is a simple straight pipe (no restriction) from the turbo directly behind the truck.

Having an exhaust without all the factory restrictions has some great benefits (lower exhaust temps, faster spool up than a turbo), but my two favorite side effects are horsepower and torque!

One thing to watch out for when finding a good exhaust system: mandrel bending. This simply means that the bends in the exhaust are made with some kind of die inserted into the pipe at the bend, to prevent bending (broken into pieces in the middle of the bend.)

When you want to maximize flow and coil times, you'll want to minimize any flow disturbances, especially where the exhaust has to go around bends and corners. This makes these types of bends far superior to crush bent exhausts, they just flow much better because the middle of the bend isn't broken and doesn't impede flow. Any good exhaust will always use mandrel bends.

Our favorite for 6.0 is this show below. This is a kit that fits all ’03-’07 Ford Powerstroke truck bed sizes.

  • Air supply kit

An air intake kit is probably the most common modification that people start with when looking for more performance, and the reason is obvious:

Engines need air and fuel to produce power. The more air and fuel, the more power, it's that simple. Having a supercharger like the 6.0 makes unrestricted breathing even more important.

Almost unlimited breathing is the goal of most aftermarket employees, and many of them are doing just that. Also, they are all very similar in shape. Since most of them will do the job of opening up the airflow, it basically comes down to differences in performance versus reliability, maintenance, and cost.

This Specter strikes the balance between form and function very well. Because of the heat shield design (which actually draws in cold air) and the reusable dry filters, I'd say it's the best entry price for the powerstroke 6.0. The main concern with many other aftermarket intake designs is that they leave the filter exposed to engine bay heat. This is a very bad idea, especially considering how hot the underfloor temperatures can get in these trucks.

The Specter kit solves the under-hood temperature problem with a thermal protection filter that pulls air out of your engine compartment like an intake always should. The design of the heat shield allows you to visually inspect the filter and makes removing it for cleaning much easier than adjusting the basic one. The rubber gasket they include prevents airflow around the heat shield, making the device draw even cooler air from outside the engine.

When it comes to reliability and maintenance, the best part about the dry filters that Specter uses in this kit is that they can be reused multiple times and never need oil. All you need is just washing with soap and water (rinsing from the inside out) from time to time. Alternatively, you can wipe the filter (outside) to remove dirt, which works well. But one thing I learned the hard way with dry filters, NEVER try to clean a filter with compressed air, you end up destroying the media and having to buy a new one (my wallet speaks from experience here.)

Best Powerstroke 6.0L Upgrades - DieselPowerUp (8)

Specter Performance Air Intake Kit: High Performance, Designed to Increase Horsepower and Torque: 2003-2007 FORD (F250, F350, F450, F550, Harley Davidson, Super Duty, Cutaway, Excursion) SPE-9973

from May 28, 2023, 11:25 a.m


  • DESIGNED TO INCREASE HORSEPOWER AND TORQUE: Dyno tested with up to 50% more airflow than the factory air restrictor and intake manifold
  • BETTER TRACTION: Improves acceleration and hill towing performance by improving throttle response.
  • IMPROVED ENGINE SOUND: Hear the power under the hood.
  • WORLD CLASS PROTECTION: Pushes the boundaries of engine protection by protecting your engine from harmful contaminants and debris
  • SIMPLE MAINTENANCE: No filter cleaning required for up to 100,000 miles
  • Garrett PowerMax Turbo nadogradnja

This turbo is a huge power upgrade, if your original turbo needs replacing or you simply want up to 175 more horsepower, look no further than the PowerMax. You will be able to install this turbo with no more hassle than installing the original Garrett that came in your truck, it is a true replacement.

Garrett is at the forefront of turbo technology, and the attention to detail in the powermax really shows their innovation. One of the coolest features is the variable flap technology they incorporated into the design, which tapers down and opens up. This greatly increases the efficiency of the turbine as the revs change, which maintains maximum power from idle to redline.

Best Powerstroke 6.0L Upgrades - DieselPowerUp (10)

Turbopunjač Garrett Powermax za 04.5-07 Powerstroke 6.0L Turbo

from May 28, 2023, 11:25 a.m


  • Supports up to an additional 175 hp over stock without sacrificing drivability Performance upgrade or OEM replacement
  • Part # 772441-5001s and 772441-5002s
  • Note: The compressor housing is NOT polished as in the picture!
  • Fits 2004.5-2007 Ford Powerstroke 6.0l (production date after 9/22/2003)
  • Compressor Inductor Wheel Diameter: 64mm Compressor Exhaust Wheel Diameter: 88mm Compressor Wheel Trim: 52 A/R Compressor: 0.58 Turbine Inductor Wheel Diameter: 73mm Turbine Exhaust Wheel Diameter: 66mm Turbine: 09 Whe Type: Stage 1 Supported horsepower: 560 hp
(Video) Double the Horsepower of your 6.0 Ford Power Stroke | Power Driven Diesel
  • Upgrade of the EGR cooler

If you still run your truck on US roads and need to keep the emissions system intact, luckily there is an option to upgrade the problematic factory EGR cooler installed on the 6.0 Powerstroke.

This cooler is a major upgrade from the factory Ford EGR cooler. Made from stainless steel and excellent TIG welds, it looks as good as it works. Internally, their design ditches Ford's factory honeycomb (which always clogs up without fail) and instead uses rounded tubes as the medium.

They pressure test their coolers to ensure there are no leaks during installation. Airtightness is something you want to be sure of when going through the trouble of installing a replacement radiator. The installation itself is a direct replacement, so there is no need to touch or modify other EGR components.

Best Powerstroke 6.0L Upgrades - DieselPowerUp (12)

Upgraded EGR Cooler Kit and Gaskets for Ford F-250 350 6.0L Powerstroke Diesel Turbo

Check the price
Best Powerstroke 6.0L Upgrades - DieselPowerUp (13)

from May 30, 2023, 2:52 p.m

  • EGR cleaning kit

This EGR Rail Upgrade Kit is the result of a new direction in EGR wiper design, addressing many of the installation and leakage issues of today's kits on the market.

It's obvious from the close-up photos of the excellent TIG welds on the tubes and the expert machining on the plate, they really have nothing to hide in the construction like you'd see with offshore replicas.

They also seem to have paid a lot of attention to the J-tube and how it connects to the adapter plate. This is the only design of its kind that I have seen and is most likely the result of the manufacturer looking at current designs and their leak points and coming up with a fix.

Best Powerstroke 6.0L Upgrades - DieselPowerUp (14)

EGR cooler upgrade kit for Ford 6.0L

Check the price
Best Powerstroke 6.0L Upgrades - DieselPowerUp (15)

from May 30, 2023, 2:52 p.m

EGR track kit for 2003-2007 V8-6.0 liter (td) Ford trucks with power stroke. This EGR track kit is a 100 percent new unit, not rebuilt. The unit is TIG welded and factory pressure tested. It can only be used temporarily to confirm faulty EGR coolers. Replaces EGR Cooler: The EGR Path Kit allows the removal of the EGR system for improved engine reliability, lower EGTs and improved horsepower. This is a "must have" for all "Race" upgrades. Durable Construction: This kit includes butt-welded 304 stainless steel coolant pipe, 14 gauge 409 stainless steel exhaust pipe, EGR valve block plate, high temperature silicone heater pipe and all associated hardware. Also Fits: Ford Excursion 2004-2005 V8-6.0L (td). Note: This is a "race only" product for racing use only. Its use is limited to closed and open road races officially sanctioned by a recognized racing organization. Any other use, including off-road recreational use, may violate local, state and federal laws. This system also requires an aftermarket electronic module to work properly with the vehicle.

(Video) The Best 6.0 Powerstroke Upgrade You Can Do To Your Truck?
  • Riser tube and dummy plug upgrade kit

If your truck is having trouble starting after it warms up, you probably have a leak in your oil system, which is causing the injectors to not be at full pressure. A very common point of leaking oil pressure is the seals on the dummy plugs, which causes the fuel pressure to be too low to get the truck started right away.

If you've checked the usual electricity suspects, such asFICM, IPR and IPC and are working as intended, then you will likely have a loss of oil pressure.

A good upgrade kit to replace the dummy plugs and swivel is this kit, it solves the problems your original dummy plugs have with worn or broken seals, sealing the oil system which will bring the fuel pressure back to normal.

Best Powerstroke 6.0L Upgrades - DieselPowerUp (16)

Genuine Ford Fuel Inlet Pipe 6E7Z-9A332-B

from May 28, 2023, 11:25 a.m


  • genuine OEM factory part
  • precise schedule
  • trajan
  • better in quality
  • this is not an afterthought
  • 6.4 Startup Upgrade

The perfect upgrade for 6.0 trucks that have very slow starters is a much better version available on 6.4 and newer trucks. Ford has revised the gear assembly on the newer starters, resulting in much faster starting times.

It's a simple replacement, nothing needs to be changed, so this upgrade is amazing if your current startup is too slow.

Best Powerstroke 6.0L Upgrades - DieselPowerUp (18)

DB Electrical SFD0122 Novi starter za 6.4L 6.4 Ford F150 F250 F350 Diesel kamion 08 09 10 2008 2009 2010 410-14080 7C3T-11000-AA 7100ZT

from May 28, 2023, 11:25 a.m


  • SUPERIOR PERFORMANCE: This replacement starter is designed to provide superior performance and reliability for increased starting power. High-quality construction and materials ensure efficient operation, providing the reliable starting performance you need.
  • FAST ENGINE STARTING: The DB electric starter is designed for fast and efficient engine starting. This automotive starter kit features cleaner, drier inner workings with sealed housings that prevent performance-degrading debris, as well as upgraded copper and silver contacts for improved performance.
  • DURABILITY: This product features high-quality materials and construction, ensuring durability and longevity even in harsh conditions. Replacement starters are designed for easy and straightforward installation, reducing downtime and operating costs.
  • COMPATIBILITY: DB Electrical 410-14080 starter is compatible/replacement for FORD: F-250 SUPER-DUTY 2008-2010, F-350 SUPER-DUTY 2008-2010, F-450 SUPER-8001, F-450 SUPER-DUTY 2008 - 2010. ABOVE DUTY 2008-2010
  • REPLACEMENT: This replacement automotive starter replaces the following OEM part numbers - ARROWHEAD:SFD0122, DIXIE:S-2156, FORD:7C3T-11000-AA, 7C3T-11000-AB, 7C3Z-11002-11002-AA810100, JC3Z-11002 Products - AA10100: , LESTER:6675, MOTORCRAFT: SA-965, PIC:150-379, USA INDUSTRIES:6670, WAI:6675N, WILSON:91-02-5926, WILSON NEW:91-02-5926
  • A set of head gaskets and a set of ARP studs

The most difficult upgrade is replacing the gaskets and head bolts with new gaskets and pins that hold everything together. Unfortunately, this is an upgrade that many 6.0 owners have had to do, and head gasket issues are the weak link in these trucks.

It's so common that there are now bulletproof kit options to replace everything this job requires, including intake flanges and all the other little flanges you wouldn't normally think of when ordering, all in one handy box with brand new ARP studs - which must be fitted. Factory bolts naturally can't have the same clamping force that stock bolts can and that's one thing you really need on a high boost 6.0.

The only thing to look out for when choosing a set of head gaskets is the manufacturing dates of your case. Basically, if your truck was built before January 14, 2006 and has t40 Torx bolts to hold the injectors - then you have 18mm studs in your heads. Of course, you should get a kit that has head gaskets to match these studs.

After January 14, 2006 and 2007, heads have 20mm studs. That's really the only problem with ordering a kit, pay attention to that and your parts will match when you go to reassemble the beast of a job.

Best Powerstroke 6.0L Upgrades - DieselPowerUp (20)

03-06 Ford Powerstroke 6.0L Diesel ARP Head Kit & OEM Style 18mm Intake Manifold Head & Gasket Installation Kit & Exhaust Gasket Kit - Package (18mm)

from May 28, 2023, 11:25 a.m


  • ARP wedges
  • MAHLE Black Diamond head gaskets
  • Main Intake Gasket Kit with Injector O-Ring and Turbo Hardware
  • Exhaust manifold gaskets
  • Intercooler tube upgrade

Factory 6.0 intercoolers are known to be a weak point. After years of sitting on top of a hot engine, they often break down and leak. The best way to deal with this is with an intercooler pipe upgrade kit like this one.

Best Powerstroke 6.0L Upgrades - DieselPowerUp (22)

Mishimoto MMICP-F2D-03BK Intercooler Pipe Kit Fits Ford 6.0 Powerstroke 2003-2007 Black

from May 28, 2023, 11:25 a.m


  • Direct fit for Ford 6.0L Powerstroke 2003-2007
  • Tube construction: Polished aluminum tube Diameter: 3.0"
  • Improves airflow, power and EGT
  • Duracore technology provides superior resistance to heat, pressure, fuel and oil
  • Mishimoto Lifetime Warranty
  • Aluminum degassing bottle and Y-tube upgrade

Another huge failure point on the 6.0 that almost always needs to be addressed is a failed coolant cap and possibly a cracked and leaking plastic degassing bottle.

Fortunately, there are many aftermarket aluminum degassing bottles that solve this problem for good. My favorite comes from Rudy's Diesel as a package. They also included an aluminum replacement for the Y pipe which is another point of failure in your powerstoke coolant system.

Don't fall victim to head gasket failure from a simple coolant leak, bulletproof your cooling system before it happens!

Best Powerstroke 6.0L Upgrades - DieselPowerUp (24)

Silver Aluminum Degas Bottle/Coolant Y-Pipe/Gold Antifreeze 03-07 6.0L Powerstroke

Check the price
Best Powerstroke 6.0L Upgrades - DieselPowerUp (25)

from May 30, 2023, 2:52 p.m



We hope this has answered your questions about performance upgrades to get you started on upgrading your 6.0 Powerstroke. If you have any questions, comments, or other news that you think should be on the list, be sure to let us know in the comments below, thanks for reading!


How much HP can you get out of a 6.0 Powerstroke? ›

In fact, the 6.0L's block, rotating assembly and cylinder heads can support roughly 700rwhp in stock form.

How much HP does a tune add to a 6.0 Powerstroke? ›

Our own testing of custom 6.0L tuning yielded 415-420 hp on the rollers—right smack-dab in the middle of what most folks see. By comparison, off-the-shelf universal tunes typically lay down somewhere between 360 and 380 hp.

What is the best tuning for a 6.0 Powerstroke? ›

SCT's X4 Programmer is hands-down, one of the most popular options for adding a programming to a 6.0 Powerstroke; and its for good reason, they work! The SCT Livewire TS can add up to 120 dyno proven horsepower and 248 lb. ft.

What is the best fuel additive for the 6.0 Powerstroke? ›

StictionRx is the best oil additive for Ford Powerstroke 6.0 and 7.3 Engines.


1. 6.0 PowerStroke Tune Up and Bulletproof Mods
(VanLeeuwen Family Farm)
2. BEST MOD 4 Ford 6.0 Powerstroke | Blue Spring Kit Upgrade Install: Fuel Pressure Regulator
(Thoroughbred Diesel)
5. Adding More Power To The 6.0 POWERSTROKE
6. no limit 6.0 powerstroke upgrade
(6.0 Bros)


Top Articles
Latest Posts
Article information

Author: Corie Satterfield

Last Updated: 17/09/2023

Views: 5742

Rating: 4.1 / 5 (42 voted)

Reviews: 89% of readers found this page helpful

Author information

Name: Corie Satterfield

Birthday: 1992-08-19

Address: 850 Benjamin Bridge, Dickinsonchester, CO 68572-0542

Phone: +26813599986666

Job: Sales Manager

Hobby: Table tennis, Soapmaking, Flower arranging, amateur radio, Rock climbing, scrapbook, Horseback riding

Introduction: My name is Corie Satterfield, I am a fancy, perfect, spotless, quaint, fantastic, funny, lucky person who loves writing and wants to share my knowledge and understanding with you.