The head gaskets themselves have always been good. The update in 2006 was for "commonization" w/ the 6.4L (Ford's story anyway). It was only to adjust for the dowel size, etc changes. Also changed was the injector hold downs and hold down bolts, These were a big improvement and help to minimize heads cracking (and fuel contamination of the coolant).

The issues w/ leaking head gaskets is due to the bolts (too few) and heat. When cylinder pressures get too high, the bolts can't keep the heads fully seated because there are too few of them. Over time, leakage gets bad enough to cause puking, high temps, etc.

Ford says there is a difference in pumps for the 2003-2004 and the 2004.25. This has been a problem for me because I have one of the 2004.25 and all the pumps I see for sale are for the 2003-2004 or the 2005 and up pumps. The 03-04 pumps start with a 3 and the 2004.25 pump starts with a 4 with all other digits in the part number being the same. The aftermarket guys sell one pump, they don't have a separate pump for the 2004.25. Ford says because the 2004.25 oil rails increased from 15 CI to 30 CI the pump was changed. My question is what was the difference between the 04 and 04.25 pumps? The 04.25 pump has seven pistons in it, does the 03-04 pump only have six or something like that?

Another GREAT write-up Mark...Thanks

Really..... nothing. So the ford techs on this site have no idea what the difference is between the 04 and 04.25 HPOP pumps even though ford says there is a difference. They also seem to not know what part of the 6.0 fuel injector goes bad, the fuel end or the oil and electrical end.

The late build 04s don't have the same HPOP that the 05 and up trucks do. These have the same top discharge HPOP that the 03s have but they share the "wavy" high pressure oil rails with the later engines. These seemingly "hodge podge" changes can be confusing if you aren't familiar with the different "flavours" of the 6.0.

Also -
On 9/29/03, the high-pressure oil rail was redesigned (wavy design) to increase oil capacity and to reduce noise. The new design wavy high-pressure rail has increased the volume from 15 cubic inches to 30 cubic inches. This reduces pressure fall-off during injection and improved emissions and fuel economy.
• The stand pipes’ serviceability has been improved.

Also as an FYI -

From the beginning of production, the high pressure pump cover retains a sleeve which provides a sealing surface for the o-ring on the high-pressure oil discharge tube.Mid-way through 2003 MY, the sleeve in the high-pressure pump cover was removed. • The sealing surface for the high-pressure oil discharge tube is now totally machined for the o-ring seal.

I know this. I have the goofy hybrid of the wavy oil rails and the old swash plate pump. So what is the difference between the 2004 and 2004.25 pumps? Ford says there is a difference, so what is the difference?

Just to add a little more detail:

The 06's and up had some turbo slight improvements as well as the "commonization". Larger oil drain tube and supply line and "A Revised Machined Recess Turbocharger (5c3z-6k682-ca) Designed Exclusively To Address Corrosion Related Turbocharger Performance Is Now Available In Service."

Also, sometime in 2005, the MAF was deleted, then added back in for the LATE-LATE '05's.

See attached documents.

ONLY the capacity of the HPOP was increased (it was the same design) - the need was caused by the extra volume in the wavy oil rails according to Ford.

You are breaking the rules of this forum. As an attorney I am sure you know how to read.

edit - deleted the quote of someone breaking forum rules. Their post was removed.

Will '06 turbo fit my '04?
 

Hello, I am going to look at a used 2006 6.0 turbo to be kept as a spare. Is there a number stamped on it that will tell me if it can be installed on my '04?
Other than some change in the mounting bracket I can't find any post saying it wouldn't work as is. I assume I can upgrade the oil feed and drain lines?
Will I find the above number stamped on the housing if it is the newer recessed design?
Thank you for all the valuable info in this forum, really a lifesaver!

04,5,6,7 turbos will all directly interchange with each other.

Thanks npcc. I picked it up yesterday and it looks pretty good. I will post some photos of it particularly of the air side intake vanes which are complete but seem a little sketchy.

What about the 08 and 09 engines 6.0L in the e-series?

I just installed a new front cover (where the oil and water pump are installed) on my '04 model year with a '05 year just to make sure the pump was the larger 100mm. I had to also change out the lower radiator hose due to the dfferent angle of the outlet pipe on the cover. The old one was pointed down at a angle and the newer one is staight out, making the old orginal hose too short..

My rep gun seems to be shooting blanks in your direction for now. Until I take a few shots at others on the site I'll have to keep the powder dry for your efforts here. Let me just thank you with a post of approval for now.
Thanks, good stuff! Tim