The 6.0L Power Stroke diesel engine was one of the features of Ward’s Top 10 Best Engines list in 2003. It did impress with its power, fuel efficiency, and emission compliance, but it was never a perfect engine. Since it’s been a while since its release and most of the units have had quite a long run, it’s understandable why so many owners are looking for a refresh, a rebuild.
With a basic engine rebuild kit, The 6.0 Powerstroke Rebuild Cost is going to cost $3k to $4.5k with labor. With upgrades, $4.5k to all the way up to $10k. When you’re buying a block engine, for short blocks you’re looking at an average of $4.5k to $5k. For long blocks, the range is $6.5k to $7k. The labor cost is taken as $100/hour on average. We’re looking at around 15 hours of labor with a rebuild kit, and around 7-9 hours for long/short blocks.
In this article, we’ve talked about the common issues with the Powerstroke 6.0L Engine, different ways to rebuild that and their cost, and how you can save money on the rebuild. Let’s dive in.
Common Issues with the 6.0L PowerStroke
The owners claim to have a love-hate relationship with their Powerstroke 6.0L. It’s a powerful engine that was introduced as the successor of the popular 7.3L Power Stroke which, however, was infamous for its less emission-friendliness issue.
The 6.0 actually solved the major deal of issues it was intended to. It was more emissions-compliant, more fuel-efficient yet more powerful, and easily exceeded the 7.3L in the performance arena. Despite making so many promises, it didn’t end up reaching the height of popularity it had the potential to, all because it had a series of common issues that Ford never really cared to address.
- EGR Clogging
Among the major problems, the EGR cooler system is probably the biggest pain in the arse. It tends to clog and is prone to failing. The engine has too small head bolts as well and due to insufficient clamping pressure of the cylinder head, head gasket failures have occurred often as so many owners reported.
- Injector Pressure Sensor
There are issues with the injector pressure sensors too. They have a very short life span and it’s not particularly easy to find them in most parts shops.
- Turbo Design Flaw
Another minor but annoying issue that many owners complained about is the design of the turbo that would stick and has to be removed to clean which involves a lot more work.
Last but not the least, the engine has excessive heat and vibration issues and the fuel injection control module has a record of failing because of that.
- Average Life Expectancy of a 6.0L Powerstroke
Keeping all the above-mentioned issues in mind, how long do we expect the 6.0L Power Stroke to last before it needs a major overhaul?
According to many popular car blogs, these powerful engines are expected to last between 200 to 300 thousand miles which is more than most owners would ever need. And this claim seems to be true.
Many owners in various 6.0L Powerstroke forums have mentioned that their trucks have done 250k-260k miles before they needed a rebuild. However, we’ve also come across instances where the engine has pretty much failed on around 150k miles. So there’s that.
And as you can already tell, it comes down to how well you maintain the engine during its stint.
6.0 powerstroke rebuild cost with Engine Rebuild Kits
You can either rebuild your engine with an Engine Rebuild Kit or you can buy the whole short or long block or the complete engine itself (though that doesn’t really count as an engine rebuild).
If the connecting rods and crankshaft and in some cases the bare block too are in bad condition and you’d like them changed, buying a block engine might be a good idea. That, however, is a pretty uncommon scenario and in most cases, an engine rebuild kit plus little things changed here and there would get the job done.
|Rebuild Kit Name & Vendor
|Dynamic Diesel Engine Overhaul Kit (Basic)
|AGKITS’ Inframe-Overhaul Engine Rebuild Kit
|Swag Performance Parts’ OEM Engine Overhaul Kit
|Kill Devil Diesel’s Overhaul Kit w/ Pistons and KDD Camshaft Kit
|Dynamic Diesel Ultimate Overhaul Rebuild Kit
|AshevilleEngine’s Mid Performance Rebuild Kit
|AshevilleEngine’s 6.0 Extreme Performance Rebuild Kit
Whether you have the necessary skills to DIY this process or not will decide if labor costs will be added to these or not. In this section, we’ll discuss the various reputed vendors that offer the 6.0L engine rebuild kits, what is included in those packages, and how much it costs to rebuild the 6.0L with just those rebuild kits.
The most affordable rebuild kit we could find is from Dynamic Diesel. This kit starts from $1460 with Mahle Head Gaskets (that you could match the size of for any Powerstroke diesel engine from 2003-2010) and no camshaft included. The factory Ford Head Gaskets will cost an additional $125.
You can add the OEM Replacement Camshaft for 390$ or the Stage 1 Callies Billet Camshaft for $650. You could also Ceramic Coat the Piston Tops for $200.
There are options to add Lifters and Fly Cut Pistons which will obviously add to the bill. You can find more about this kit here. This kit is configurable to fit any 6.0 Ford Power Stroke diesel from 2003-2010.
AGKITS’ Ford 6.0L Powerstroke Inframe – Overhaul Engine Rebuild Kit
Next up, we have the inframe-overhaul engine rebuild kit from AGKITS which starts from $1625. This price is for the overhaul kit with 18mm Head Dowels and without head bolts.
The same configuration but with the head bolts will cost $70 more, 1695 dollars.
For builds 2004-2010, this configuration (18mm Head Dowels, Cylinder Head Bolts included) will cost $1960, and if you need the 20mm Head Dowel option, the price will bump up to 2515 dollars.
This kit from Swag Performance Parts costs $2250 after some discount and comes with a 2-year warranty. It Fits 04.5-10 6.0L Powerstroke Diesel Engines.
You get what you expect from a standard engine rebuild kit (Piston sets, Rod & main bearings, cylinder head bolts, and gasket set) and there are not many customization options available. However, they offer oversized pistons as per request for late builds.
Next up, we have the 6.0L Powerstroke Overhaul Kit w/ Pistons and KDD Camshaft Kit from Kill Devil Diesel. It starts from $2800 where you get a Stage 1 or Stage 2 camshaft with non-coated pistons.
You can take a stage 3 camshaft for an additional $300 and coated pistons for another $300. 18mm and 20mm Gasket sizes are available that are made by Ford. The bearings are from Mahle but it might be substituted by Ford bearings if Mahle is not available. The Pistons and rings are from Mahle as well.
We’ve discussed one from Dynamic Diesel already which was the most budget-friendly option but this one serves a different purpose. As you can tell from the name “Ultimate”, this features a wider range of parts and options.
You know what’s the most important bit about this kit? That you will get a t-shirt of your preferred size included in the kit. Kidding. But yes, they do include a t-shirt as a gift which is not there in the standard rebuild kit.
Apart from this ‘Crucial’ addition, you get things like Steel top ring groove which is perfect for street strip trucks over the long haul, Plasma coated steel top ring, 16- HD lifter set, Mahle complete upper and lower gasket set, Grafal moly-based friction coating on skirts, etc. with this Ultimate rebuild kit that starts from $3199. You also get the option to add the Form OEM oil cooler for an additional $300 and ARP head studs for an additional $515.
Finally, we have the rebuild kit that’s certainly not for everyone. Presenting the Extreme Performance Rebuild Kit with Straub cam & Wagler rods from Asheville Engines that is priced at $8780—yes, that’s right.
This is made for enthusiasts that might want to pull a sled over 300 feet or 1,000+ horsepower dyno performances from their engine.
It comes with a balanced crankshaft, Straub Technologies stage 2 camshaft, thermal coated pistons and rings, Wagler billet connecting rods, calico coated rods, cam and main bearing sets, high rev valve spring set, valve lifters, and everything you could ask for extreme performance. If you have the money to spend, this is one of the most outrageous rebuild kits you could get for your 6.0L Power Stroke.
AshevilleEngine also offers a mid-performance rebuild kit that we thought was a great option too and provides better value for the buck. At $4490, this can be a great sweet spot between people looking to extract great performance out of their 6.0L Power Stroke and those who’re looking to push it to the extreme.
You still get the Stage 2 Camshaft, the balanced crankshaft, the valve lifters, and other essentials that are needed to extract amazing performance out of your Power Stroke.
Another obvious way to meet the purpose that you’re rebuilding the engine for is to buy a short or long engine block that comes with more parts or buy a complete engine itself. A good number of reputed manufacturers offer replacement 6.0L Power Stroke engine blocks or engines for your truck.
|Short Block, Long Block, Drop-in
|J & K Engines
|Short & Long Block, Performance Packages
|Kill Devil Diesel
|Short Block, Long Block, Drop-in
|Used ‘Ready to Run’
Below, we’ll look at a few great options and their cost in detail.
Asheville Engines sells 6.0 Power Stroke diesel engine blocks too along with the mid and extreme-level rebuild kits we just discussed. For customers who need to get the job done quickly, they offer a complete drop-in engine manufactured to original Ford OEM specifications with the ARP studs added for $13,495.
Their range of engine blocks starts from $3445 only for the 18mm & 20mm short block options. It’s a properly remanufactured engine block with connecting rods and pistons.
The 6.0 long block assembled with ARP head studs is going to cost you $5395 and you have to put in a refundable core deposit when you shop any of the mentioned options from them.
J & K engines is another popular vendor to shop for remanufactured Power Stroke engines. They sell 5 versions of the 6.0L Power Stroke engine blocks. The most affordable, short-block engine is going to cost you $3595.
The long block engine goes for $5295 and ARP head studs are included in the package.Apart from that, they offer 3 performance packages. The stage 1 6.0L Powerstroke is going to cost $6045 that comes with ARP head studs, O-Ring Cylinder Heads, and a Billet Chromoly pushrod set.
The stage 2 6.0L Powerstroke is going to cost $7275 that comes with a Stage II Camshaft and Hi-Rev Valve Springs along with the offerings of the stage 1 performance package. And, the stage 3 6.0L Powerstroke is going to cost $9425 that comes with ARP Main Studs, Coated Main, Rod, and Cam bearings, Balanced Rotating Assembly & Coated HD piston set along with everything included in the stage 2 performance package.
Kill Devil Diesel sells a wide range of 6.0L Powerstroke engine packages and the pricing of the highest-performance “Level 3, Ready to run” engine goes for $20,524. It includes a Stage 3 KC Turbo and you have the option to have the Bullet Proof EGR Cooler for an additional $350.
This monster 6.0L produces an outrageous 650hp!! That’s crazy! That, however, is not what most people are looking for. We’re looking for sane engine blocks and that’s what we’re going to focus on for now,
The range starts with the Standard Short block version that goes for $4450. You can, however, customize the package, i.e. include Wagler connecting rods for an additional $3000. There are other customization options available including piston coatings and premium lifters.
Asheville Engines usually is far from the stock and the long block 6.0L engine they offer comes with several upgrades and starts from $9975. You can have a different engine package, upgrade the connecting rods or have a cylinder head made of KDD ICON Aluminum or KDD Ported ICON Aluminum if you want to. And if you’re looking for a little bit more affordable “Ready to run” engine, you can buy a 450HP complete crate “Stock Plus” engine for $14,225.
On their eBay store, Blackwater engines have a range of 6.0L engine blocks listed that you could check out for affordable options. For example, their long block goes for $5060 which is comparatively cheaper. They also offer a 2 years unlimited miles warranty on that when the engine is moving a 1-ton truck.
They also have a complete running diesel engine from the OEM manufacturer for a 2-year unlimited miles warranty. You have the option to upgrade to ARP head studs for an additional $550. However, the price is not mentioned.
So, you have another option apart from the 2 discussed where you may end up saving a good amount of money. You could buy a used engine that’s in good shape.
To give an idea of how much you might save on a used engine, Diesel Redemption is selling this complete drop-in stock engine for $5995 only. This engine comes from a municipality-owned vehicle and they claim it was well maintained, has low mileage, and was rigorously tested for performance.
If you compare that to how much a complete drop in condition engines costs from the other vendors we discussed above, you can clearly see that you’ll get the job done with half the money. So buying a used engine could be such a great option if you shop around and be able to find reputed, trusted used engine vendors and get the engine checked thoroughly by an expert.
How to Save Money on Your 6.0 powerstroke rebuild ?
Here’s the thing—there’s no fixed price when it comes to auto repair costs. If you put in the thoughts, time, and effort to look around for options, you can always save some money.
Here are a few ways you can save money on your 6.0L Power Stroke Rebuild:
1. Control Temptation, Buy Only the Rebuild Kit You Actually Need
There are so many killer rebuild kits available with so many upgrades. If you’re somewhat of an enthusiast and love a powerful engine, it’s hard to resist Stage 1 or 2 or 3 packages.
Is that really what you need— ask yourself this question.
So many times, we just end up having raw power in our machine but never really utilize it fully. It’s always satisfying to know that you have the horsepower under the hood but if you don’t really use it, the power isn’t of much help.
Remember, the stock 6.0L is already a powerful engine and will suffice for most people’s needs, as it has done for you for all these miles before you thought of the rebuild. So if you don’t really need it, don’t end up spending a lot of money on upgraded packages.
2. Shop Around
As said earlier, when it comes to engine works, there’s no fixed price. You want to shop around for everything in order to understand the market and save some money.
If you’re rebuilding from a kit, you should shop around for different vendors. If you’re taking quotations from a garage and leaving everything to them, again shop around for better quotations. Talk to other owners for garage recommendations and to verify whether a quote you’ve got seems justified or not.
Shop around for more affordable labor as long as they’re qualified enough to dissect your engine. Just put in the effort and shop around and you’ll end up saving some good money.
Probably the most obvious way to save a good chunk of money is to DIY the project to the extent you can when you have the necessary skills and tools.
You probably won’t pull it off completely by yourself mostly because of not having all the required machines or tools but hey, for this project the labor cost is going to be at least ~$1500. If you can save half or two-thirds of that, it’s still great.
If you’ve got an expert friend to guide you through, that’s even better.
However, for a word of caution, you should only attempt this if you’re confident enough with your skills and are well-equipped for the job because the engine is a complex piece of machine and requires finesse. Don’t mess it up.
No matter which rebuild kit you use to rebuild your engine or get it done from a local shop, it is not going to be cheap as you can already tell. When building from the cheapest rebuild kit we featured today, it’s still going to cost $3 to $3.5k.
Before you decide on rebuilding, you want to reconsider whether you actually need a rebuild or not. We’re saying this because we’ve seen cases where the owner didn’t really need a rebuild but did it anyway because of not having adequate knowledge and for that “refresh and feel-good vibe” that comes with engine rebuilds.
It’s a lot of money to spend just for that.
You see, anything on the top end (valves, heads, etc.) is just a pull-and-replace thing. In the case of a bad lifter, you could still get things done without a complete rebuild. Was it a front or rear lifter? What shape is the camshaft in?
There are many other cases where a rebuild is not really necessary. Obviously, for a worn-out piston set where you’re losing excessive amounts of compression, for a thrown rod and spun bearing, you should strongly consider a rebuild.
It’s just wise to reconsider and talk to an expert before you freeze on your decision of rebuilding your 6.0L Power Stroke.
Conclusion – 6.0 Powerstroke Rebuild Cost
There you have it. As you can tell, the cost of rebuilding your 6.0L Power Stroke engine depends on a lot of variables. To sum things up for you, with a basic engine rebuild kit, The 6.0L Power Stroke Rebuild Cost is going to cost $3k to $4.5k with labor.
With upgrades, $4.5k to all the way up to $10k. When you’re buying a block engine, for short blocks you’re looking at an average of $4.5k to $5k. For long blocks, the range is $6.5k to $7k.
Nasruddin is a passionate car enthusiast with a love for troubleshooting and diagnosing all sorts of vehicle problems. With years of experience in OBD diagnostics, Nasruddin, has become an expert in identifying and solving complex automotive issues.