I have a 2006 F250 6.0 CCLB with 230K on it. As far as I can tell, it is completely stock, aside from a K&N intake and an aftermarket muffler. The truck was having issues, so I rebuilt the turbo, replaced the plastic CAC pipe, replaced the MAP, FICM, blue spring mod, VGT valve, and maybe a couple other things I am forgetting, but so far I am ~7K out for the truck. I have ~2K for parts and diagnostic tools.

The main issues with the truck, from what I could tell, is I have one cylinder with failing rings, although is runs on all 8, and I probably have injectors that are on their way out, sensors not working correctly, poor fuel economy (best I got was 14.8 doing about 65 on the highway, the whole tank), with about a 10-11 mpg average, its not bulletproofed, was low on power (I parked on a hill and had to floor it for about 30 seconds before the truck even thought about moving, all while dumping black smoke), although once moving, it was okay, smokes at elevations above ~4000ft, and seems to have a HPOP issue, or a leak somewhere in the HPO system.

Yesterday, I went to pull my trailer forward a couple feet, started the truck, it had a slightly longer crank than usual, started backing up the 2 ft to the trailer, and the truck stalled. I checked the oil and saw it was at the bottom of the dipstick, so I figured the HPOP wasn't getting enough oil. I hooked up my X4 and it had a ICP pressure too low code, and it was smoking black while cranking. I had this happen once before, so I figured no problem, it just needs some oil. I filled it up to the top of the hash marks, and I could not get the truck started. LPOP was working, according to the dash, FORScan was showing the HPO system was where it needs to be, and everything seemed to be in check. It came really close a couple times, but no go. Ether, no ether, didn't matter, it wouldn't start. I tried all day, running the batteries down many times, and while I almost got it started, I could not get it to run. It initially was smoking black, but then nothing. Almost nothing was coming out of the exhaust. A very light haze could be seen in the pipe, but that's it. I also no longer see a reading on the oil pressure on the dash, although the high pressure oil system still was giving readings. Its at the full mark for oil, has fuel, clean filters, but the darn thing won't start.

I knew the engine was not going to last much longer, and I don't want to tear the top apart, just to need to get the lower assembly rebuilt anyway. This is the first time this truck has lived up to the Ford 6.0 PSD name, of leaving me stranded, although its in the driveway right now.

My questions are, as the title says, should I rebuild it, or replace it? I have some money in the truck already, and know, at least in part, what's wrong with the engine. I could get a used 6.0 for 3-4K, but that would be an engine that has not been rebuilt or bulletproofed, although it would be known to run correctly. Part of me wants to do that, as I know the sensors and injectors would be in a working state, but I also know, it would be a matter of time before it needs something major. I can't seem to get a solid price on a rebuild kit, as I don't know which ones are worth it, or not. I figure right now, with a stock rebuild kit, ARP studs, injectors, and maybe a new oil cooler and egr cooler, I would be looking at 5-8K, but I really don't want to drop that into the truck. At that point I could have, and maybe should have, bought a Dmax or Cummins. The only thing I know I can't do is the machining, and if the block is not too scored, I think that would be about 1K (included in my estimate), but I guess I won't even know what I need until it gets torn down. For all I know there is a deep gash in one of the cylinder walls, where the block would need a sleeve or is shot.

Assuming I go the rebuild route, which would be more fun, and I would literally have blood sweat and tears in it, what rebuild kit should I use? I am not looking to do anything crazy with the truck. At most I would do a light tune, but I usually like my vehicles stock. I don't care for smoke, 500HP, 1000lbft torque, or whatever else people may do that makes no sense to me. 50hp tune to get me at 375hp, maybe, but thats pushing it for me. I have a trailer that is between 5-10k lbs, and that would be moved once in a while, but that's about it for a challenge. The rest of the time would be either sitting, or moving construction material in the bed. I don't DD a truck, I have a diesel car for that.

Hopefully my post isn't too long, and maybe I can get some good input here. Thanks

 

Curious how you know you have a bad cylinder. Compression test or did you scope it?

 

Blowby, occasional contribution code on cyl2, I can hear a skip when starting, etc.

 

Rebuild it yourself and don't trust a machine shop to do it. Have them do the machining, but you do the assembly. There are too many videos on YouTube on how to properly assemble these engines.

I rebuilt the one in my buddy's 2007 and he was appalled at how much better it ran. I resealed evening better than when it left the Navistar plant back in 2006.

 

Any recommendations for a rebuild kit? I am going to try and have the engine out of the truck by the end of the week.