The main truck for my job is a 2004 E series cube with a 6.0. The first engine melted the internals of the oil filter it got so hot, the second engine blew head gaskets after only a few weeks of driving, replaced with Black Onyx (now we know bad idea) and ARP head studs. It has a EGR delete, and we just put a new oil cooler on.

Is there anything else we should be doing now that we (just my boss and I pulled the cab and engine apart, and we are not mechanics by trade) need the cab off to do. My boss wants it as reliable as possible. We know the gaskets had issues, could see the problem when we removed them. From what we have figured out, factory gaskets are the way to go, but is there any other option? Anything better?

Also, anything, no matter how difficult or pricey, we should be considering now? We do not want to pull this thing apart again. We have the heads at a machine shop getting pressure tested, and they will also be checking the block for flatness.

 

I'd check the heads to make sure they're flat/true. The block generally isn't the problem. With the EGR cooler out of the way, head studs and OEM gaskets...maybe upgrade your fuel pressure regular spring (blue spring mod). Other than the filters, shouldn't have much else to worry about for a long time.

 

Easy to replace your stand pipes and dummy plugs on the 04. Could prevent leaks down the road. The new ones have teflon washers to stiffen the o-rings. Should be plenty of threads on them to research for PNs. Also, may want to consider replacing the HPOP now. 04's tend to go out and that would leave you stranded. It's not too bad a job to do it later, but it most likely will fail at some point.

 

Go here BulletProofDiesel - Darn-Near Bullet Proof Diesel Products for your 6.0

 

Is the HPOP original?

 

Not sure about the HPOP, I think its from the donor engine. If so, it had 32000 miles or so, but has sat for a while in a yard.

So far we have:
New dummy plugs and stand pipes (new upgrade version)
blue spring kit
ARP studs
Factory head gaskets
HPOP screen (old one had PINE NEEDLES in it, WTF?)

Looking for information on new turbo oil drain tube, what is different the original, is it the same on the E series as F series, and should we get new one.

By the way, Thanks to all who are helping, with this thread and my previous thread.

 

If money was no object, If It was me, I think that I would do a coolant flush & replace it with ELC. Cat EC1 rated. Then I would put a BPD bypass oil cooler system on it. I am sure that there are some people that may disagree with me, but that is what I wiuld do.

 

Coolanty filter is a good and cheap upgrade.

 

To go along with other threads...make sure your using the right oil filter cap and make sure the batteries are good.