The EGR System: the 6.0L's Achilles Heel
The source of many, if not most, of the 6.0L's reliability issues is undeniably its EGR (Exhaust Gas Re-circulation) system. The EGR cooler and oil cooler both have a penchant for clogging up, which caused overheating which could lead all sorts for fun things like oil pump or turbocharger failure. That's why one of the most popular upgrades for the 6.0L Powerstroke is an aftermarket EGR cooler or EGR delete. These systems improve the function of the EGR system or completely eliminate it, which solves the issues that could easily kill a lot of the 6.0L's component parts, if not the engine itself. You can find both over in our 6.0L Solutions Section.
Stronger Head Gaskets and Studs
Oil System Upgrades
If and when you get your 6.0L Powerstroke squared away with an EGR upgrade, head studs, and head gaskets, you can move on to modifications. Like all big diesel engines, the 6.0L Powerstrokes respond remarkably well to performance PCM tuning which can add up to a whopping 100 horsepower and 200lb-ft of torque when combined with a cold air intake and exhaust upgrade to keep EGTs in check. Tuning is by far the best bang for your buck when it comes to power on these trucks, and we have a ton of different tuner options over in 6.0L Powerstroke Tuner Section.