Head Gasket Tips for Ford’s Diesel 6.0 Powerstroke

The 6.7L Powerstroke diesel engine from Ford is known for its raw power and torque, but it also comes with a fair share of challenges—particularly when it comes to head gaskets. If you own or are considering buying a Ford Super Duty truck with a 6.7L Powerstroke engine, understanding how to handle head gasket issues is essential for maintaining performance and reliability.

In this article, we’ll cover common symptoms, repair tips, upgrade advice, and best practices for managing head gasket issues in the 6.7 Powerstroke diesel engine.

Why Head Gaskets Fail on the 6.7 Powerstroke

The 6.7L Powerstroke has a reputation for blowing head gaskets. This isn’t always due to poor manufacturing but rather a combination of high cylinder pressure, insufficient clamping force from the factory head bolts, and issues with the EGR (Exhaust Gas Recirculation) and cooling systems.

Key causes include:

  • Weak Factory Head Bolts: The stock torque-to-yield head bolts can stretch under extreme boost or towing conditions, leading to head gasket failure.

  • Overheating: A clogged oil cooler or failed EGR cooler can cause excessive engine temperatures and crack or warp the cylinder heads.

  • Tuning and High Boost: Aftermarket tuners that increase boost and horsepower can put added strain on the head gasket and head bolts if supporting upgrades aren’t in place.


Symptoms of a Blown Head Gasket

Detecting a head gasket problem early can save you a lot of time and money. Common signs include:

  • Coolant Loss Without Visible Leaks

  • White Smoke from the Exhaust (Especially at Startup)

  • Bubbling in the Degas Bottle (Coolant Reservoir)

  • Oil Contamination (Milky Oil)

  • Engine Overheating or Temperature Spikes

  • Loss of Power or Poor Towing Performance

If you’re experiencing any of these issues, it’s important to perform a compression test or cooling system pressure test to verify head gasket integrity.

Upgrading vs. Replacing with Stock

When facing a head gasket replacement, you’ll have to decide whether to stick with OEM-style components or go for an upgrade. Most Powerstroke owners and experts recommend upgrading the head gaskets and head bolts at the same time to prevent future failures.

Upgrade Recommendations:

  • Head Studs (ARP): Replacing factory bolts with ARP head studs is the gold standard. Studs provide stronger clamping force and are reusable.

  • Multi-Layer Steel (MLS) Head Gaskets: These provide improved sealing under high pressure and are often used in performance or heavy-duty applications.

  • EGR Delete or Upgrade: A faulty EGR cooler can cause coolant to enter the combustion chamber. Upgrading or deleting the EGR system can enhance reliability.

  • Upgraded Oil Cooler: A clean, efficient oil cooler helps keep engine temperatures in check, protecting the head gaskets and other components.

Tools You’ll Need for the Job

Replacing head gaskets on a 6.0 Powerstroke is a labor-intensive task, often requiring 20–30 hours of shop time. If you’re a DIY enthusiast, be sure you’re fully equipped with the right tools:

  • Torque wrench (with angle gauge for studs)

  • Engine hoist or lifting equipment (for cab removal, if needed)

  • Head gasket kit (preferably MLS)

  • ARP head studs

  • Gasket scraper and cleaning tools

  • Coolant and oil for fluid replacement

  • Shop manual or digital repair guide

Optional: Many choose to remove the cab for easier access. While not strictly necessary, it can significantly reduce the time and frustration involved in the process.

Head Gasket Replacement Tips

Whether you're replacing a failed gasket or upgrading as preventative maintenance, here are key tips to ensure a reliable repair:

  1. Check Head and Block Flatness:
    Before reassembly, ensure the cylinder head and engine block surfaces are perfectly flat. Warped heads should be resurfaced or replaced.

  2. Clean Everything Thoroughly:
    Even a small amount of debris or residue can cause a poor seal. Use proper solvents and scrapers to clean gasket surfaces.

  3. Install ARP Head Studs Properly:
    Follow ARP’s torque sequence and specifications exactly. Improperly torqued studs can cause gasket failure or head warping.

  4. Replace Other Wear Items:
    While the engine is apart, it’s a good time to replace valve cover gaskets, glow plugs, injector seals, and other wear components.

  5. Flush Cooling System:
    If the head gasket failed due to overheating, flush the cooling system to remove debris and contaminants.

  6. Monitor After Repair:
    After reassembly, monitor your coolant levels and temperatures closely. Consider adding a coolant filtration system for added protection.

Estimated Costs

Head gasket jobs on the 6.0 Powerstroke can vary significantly in price:

  • DIY Parts Cost: $900–$1,500
    (Includes head gaskets, head studs, coolant, oil, and seals)

  • Professional Repair: $3,000–$5,000+
    (Depending on shop rates and additional repairs)

Going with quality parts and experienced installation is worth the investment to avoid repeat failures.

Preventive Maintenance for Longevity power stroke diesel engine

Want to avoid ever having to replace the head gaskets  power stroke diesel engine These practices will help extend the life of your 6.0 Powerstroke:

  • Regular Coolant Flushes

  • Use High-Quality Coolant and Oil

  • Install Monitoring Gauges (EGT, Coolant Temp, Oil Temp)

  • Address Overheating Issues Immediately

  • Avoid Aggressive Tuning Without Supporting Mods

  • Upgrade Oil and EGR Coolers if Needed

Conclusion

The 6.0L Powerstroke may have a reputation for head gasket problems, but with the right upgrades and maintenance, it can be a powerful and reliable engine. Investing in ARP studs, MLS gaskets, and high-quality cooling system components pays off in long-term durability—especially for trucks used for towing, hauling, or performance builds.

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