Hello,

I have an 2003 F250 6.0L which had a bearing go out, so I had to buy a used 6.0L to replace it.. The one I received was from a 2004 F250 6.0L, but there seems to be a compatibility issue between the two.

On the bad 03, an "oil pressure sensor" is mounted to the intake manifold, and on the new 04 6.0L this sensor is mounted to the valve cover. We tried the to swap valve covers but the head bolt pattern seem to be different, as well as the wiring harness/wires the "oil pressure sensor" also appear to be different.

Is anyone familiar with scenario? Will I have to send the 04 6.0L, or is there a work around?

Thanks in advance,

Greg

 

I am with you its the ICP sensor

2003 had the ICP in the High Press Oil Pump

Where your 04 has the ICP in the Passenger Valve cover

You need an 04 Engine wire Harness to make it work

Or I guess you could rewire the ICP sensor to be abel to plug into the passenger valve cover

 

Yep get a new harness is likely your best bet.

 

MISTAKE!! On my part.

 

Cool. Is that the only compatibility issue with the 04 6.0L in 03 chassis?

Thanks,
Greg

 

That is the part number for the EGR valve.

 

And to the OP, you are far better off sending the donor engine back, and continuing your search for a 2003 engine, in order to keep things simple.

 

I went out to my garage and grabbed the wrong stupid box!!!!! Didn't have my flash light!!! Sorry folks.!

 

Thanks for the tip. What other problems might I run into with this engine?

 

I'm not sure of what problems you might run into with using this engine, so I guess the best way to put it into perspective is to run down with the KNOWN differences between your engine and a late-2004 engine.

-Injectors although VISUALLY identical are two different part numbers. Others have reported interchanging between the two with no issue, but the fact that 2003 engines use a specific number exclusive to 2003, tells me there are differences. I'm not sure if the two engines that run different ICP pressures would have anything to do with this as well. 2003 engines typically idle at about 620 psi of ICP pressure while late 2004 and up engines idle at about 580 psi.

-As far as internal engine parts, the 2004 uses wavy high pressure oil rails, and consequently different rocker arm carriers, standpipes and branch tube. To change just any of the above mentioned parts is a major undertaking, even with both engines out.

-the engine harnesses are consequently different between the two, due to the obvious different locations of the ICP sensor, but more importantly the 2004 uses an EGR throttle plate, while the 2003 uses a "dummy" throttle plate housing with no actual plate inside. This means the PCM calibrations between the two engines are different, along with the other above mentioned reasons.

You COULD still make this engine work, but in order to do so, would mean extensive disassembling of the donor engine, and transferring of all 2003 specific parts, which would mandate the purchasing of the necessary gaskets for doing this, only further escalating the cost of the "surgery".

 

The engine came 'loaded' with all 04 6.0L engine parts, so do you think the injectors will be OK? Which other parts do you think I should swap over, I really don't want to have to do any major surgery, lol? In my mind, the biggest potential issue could be the PCM in the 03 chassis might not be 100 percent compatible with the 04 engine.

 

As I've already indicated in the post above, the injectors between the two model years are different. I understand the engine came "loaded", but all the parts I've listed above are different between the two model years. Regarding the two PCM calibrations, they are completely different between 2003 and 2004. Yes, it IS major surgery to to disassemble the two, side by side to transfer all the 2003 specific components onto the donor engine. Major enough, that you need to evaluate whether it is worth the trouble of going ahead with it, or waiting out another donor engine that is of 2003 model year.

 

Sorry for my newbness, I'm not a mechanic, but I'm not understanding why putting the 03 injectors inside the 04 motor is nessesary (or am i misunderstanding you?)... the 04 6.0L injectors are inside the 04 motor, inside the 03 chassis. Which parts might be negatively impacted by this? If it's just the PCM, could I just put a 04 PCM int he 03 chassis?

Returning the motor isn't really a convienent option.

 

Agreed.

Get a new harness. There are 2 different harnesses for the 04 motor and I'm not exactly sure what or why they are different, but they still connect to the PCM and sensors the same. If your 04 motor came with a harness it would be a major plus. It's possibly a serial number/production plant difference.


Contact Powerhungry Performance about getting the PCM recalibrated to an 04 strategy as the 03 and 04 use the same processor. They can send you a unit to reflash your PCM, TCM, and FICM that will be well worth your $$$.

I'm going to have to disagree with Mike on the transplant being a difficult thing, especially if you have a complete motor "in hand". Folks have put 05+ motors in the 03's without much difficulty. I'm going to be transplanting an 03 block into my 04 sometime this summer so maybe I should do a write up with what's involved.

 

Thanks for all the help. I'll report back on how it goes.


Greg