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v3 Complete Solution

2003–2007 Ford 6.0L Power Stroke

6.0 Power Stroke Basic & Complete Solution Kits

Fix the oil cooler and EGR cooler with the Basic Solution™, or add ARP head studs and head gaskets with the Complete Solution®. Confirm your EGR cooler style and head gasket size below, then pick your kit.

Identify my EGR cooler Shop the kits
Sinister Diesel Basic Solution™ kit components for the 2003-2007 Ford Powerstroke 6.0L
Basic Solution™ kit, 6.0L Power Stroke

Not sure which kit you need?

How to Choose the Correct 6.0 Power Stroke Solution Kit

The Ford 6.0L Power Stroke changed during production. Before you order, confirm which EGR cooler and head gasket configuration your engine uses. Model year helps narrow it down, but it isn’t always the final answer—especially if the engine, cylinder heads or other major parts were replaced. Use the guides below.

Fixes: oil cooler + EGR cooler

Basic Solution™ Kit

Replaces the oil cooler and the EGR cooler (round or square) together, with the gaskets, O-rings and hardware to do the job. See the 6.0 Power Stroke Basic Solution kit.

Fixes: oil cooler + EGR cooler + head gaskets

Complete Solution® Kit

Everything in the Basic kit plus ARP head studs and 18mm or 20mm head gaskets, so the head gasket repair and both coolers are done at once. See the 6.0 Power Stroke Complete Solution kit.

Step 1: EGR cooler

How to Identify Your 6.0 Power Stroke EGR Cooler

Round vs. Square 6.0 Power Stroke EGR Cooler

The 6.0L uses two EGR cooler designs that differ in size and shape. Look at the body of the cooler on your engine and pick the one that matches.

Round style EGR cooler for 2003 and early 2004 Ford 6.0 Power Stroke
Round EGR cooler · 2003 / Early 2004

Round EGR Cooler

  • Generally found on 2003 engines and some early-production 2004 engines.
  • The main cooler body is round and cylindrical.
I HAVE THE ROUND STYLE
Square style EGR cooler for late 2004 through 2007 Ford 6.0 Power Stroke
Square EGR cooler · Late 2004–2007

Square EGR Cooler

  • Generally found on later-production 2004 engines and 2005–2007 engines.
  • The main body has a larger rectangular or square profile.
I HAVE THE SQUARE STYLE

Have a 2004 6.0 Power Stroke? 2004 was a transition year, so your truck may have either cooler. Don’t choose by model year alone—look at the EGR cooler installed on your engine before ordering.

Step 2: Head gaskets (Complete Solution® only)

How to Identify 18mm vs. 20mm 6.0 Power Stroke Head Gaskets

The Basic Solution™ does not include head gaskets. It replaces the oil cooler and EGR cooler only, so skip this step if you’re ordering the Basic kit.

Check the manufacture date on the driver’s door label.

Built on or after January 2006 = 20mm dowel pin head gasket. Built before January 2006 = 18mm dowel pin head gasket.

What Does 18mm vs. 20mm Mean on a 6.0 Power Stroke?

It refers to the cylinder head locating dowel configuration, not the thickness of the head gasket. The head gaskets and cylinder head parts must match your engine’s dowel configuration.

Replaced engine or heads? Many 6.0L trucks have had a replacement engine, replacement cylinder heads or an earlier head gasket repair. Don’t assume every early truck is 18mm or every late truck is 20mm—if the repair history is unknown, verify what is installed before ordering.

Need help identifying your engine?

Have your truck year, VIN, engine serial number, engine build information and any engine or head replacement history ready.

NEED HELP IDENTIFYING YOUR ENGINE?

At a glance

Quick 6.0 Power Stroke Fitment Guide

What you need to identify Common application Best way to verify
Round EGR cooler 2003 and some early 2004 engines Visually inspect the cooler body
Square EGR cooler Later 2004 through 2007 engines Visually inspect the cooler body
18mm head/dowel configuration Common on earlier engines (door date before January 2006) Engine configuration or physical measurement
20mm head/dowel configuration Common on later engines (door date January 2006 or later) Engine configuration or physical measurement

Fitment Note: Production changes, replacement engines, and previous repairs can affect which components are installed. When in doubt, verify the parts currently on the engine before ordering.

Learn more

How to verify 18mm vs. 20mm on your engine

Start with the manufacture date on the driver’s door label (built on or after January 2006 = 20mm; before January 2006 = 18mm). Then confirm the installed parts:

  • With the heads removed, measure the locating dowel: 18mm is about 0.709 inch, 20mm is about 0.787 inch.
  • With the engine assembled, the engine serial number and cylinder head hardware can help. The engine serial number is on the rear driver’s side of the engine block.
  • On an engine with its original FICM, identification information may also be on the FICM label.
Why model year alone isn’t enough

Most 6.0L trucks are now nearly two decades old. Many have received replacement engines, replacement cylinder heads, earlier head gasket repairs, updated Ford parts or remanufactured engines. Model year and production information are useful starting points, but when the repair history is unknown, verify what is installed before ordering.

Round vs. square EGR cooler: buying the cooler on its own

Browse all Power Stroke EGR coolers and components or the full 6.0L Power Stroke parts category.

What’s in the Basic and Complete Solution kits

Basic Solution™: Sinister Diesel EGR cooler (round or square), updated oil cooler and screen gaskets, intake gasket, and turbo hardware and O-ring kit. Backed by Sinister Diesel’s 2-year warranty.

Complete Solution®: Sinister Diesel EGR cooler (round or square), updated oil cooler, screen and oil cooler gasket kit, ARP head studs, head gaskets (18mm or 20mm), intake gasket, and turbo hardware and O-ring kit. Orders with ARP studs require the billing and shipping addresses to match.

Only need the oil cooler? See the Sinister Diesel 6.0 Power Stroke Heavy Duty Oil Cooler. Planning the job? Find guides on our installation instructions page.

IMPORTANT FITMENT DISCLAIMER: Always verify the components currently installed on your engine before ordering. Model year and production information are useful identification tools but may not accurately represent engines or cylinder heads that have been replaced or modified during previous repairs. If you are unsure which configuration you have, contact Sinister Diesel before ordering.

Step 3: Pick your kit

Choose Your 6.0 Power Stroke Solution Kit

Each kit opens its product page with current price, availability, fitment and full kit contents.

Round EGR cooler kits (2003 / early 2004)

Basic Solution™

Complete Solution®

Square EGR cooler kits (later 2004–2007)

Basic Solution™

Complete Solution®

Prefer to choose your options on the product page?

Pick the EGR cooler style (and head gasket size for Complete) on the product page.

Before you order

6.0 Power Stroke Solution Kit FAQ

How do I know if my 6.0 Power Stroke has a round or square EGR cooler?

The most reliable method is to visually inspect the EGR cooler currently installed on your engine. Early engines generally use a round-style cooler, while later engines use a larger square-style cooler. 2004 was a transition year, so 2004 owners should verify before ordering.

Does a 2004 6.0 Power Stroke have a round or square EGR cooler?

It can have either. Early-production 2004 engines may use the round EGR cooler, while later-production 2004 engines generally use the square EGR cooler. Visually checking the installed cooler is the safest way to confirm.

What is the difference between an 18mm and 20mm 6.0 Power Stroke head gasket?

18mm and 20mm refer to the cylinder head locating dowel configuration, not the thickness of the head gasket. The head gasket and related components must match the cylinder head and engine configuration.

How do I know if my 6.0 Power Stroke is 18mm or 20mm?

Start with the manufacture date on the driver's door label: trucks built on or after January 2006 use the 20mm dowel pin head gasket, and trucks built before January 2006 use the 18mm. If the engine or heads may have been replaced, physical verification is the safest method. With the heads removed, the dowel diameter can be measured directly.

Can I determine my 6.0 Power Stroke head gasket by model year?

Model year is a useful starting point, but it is not absolute. The manufacture date on the driver's door label is a better guide than model year, and many trucks have had replacement engines or cylinder heads, so verify the installed configuration when the repair history is unknown.

What if I still don't know which 6.0 Power Stroke kit I need?

Contact Sinister Diesel before ordering. Providing your VIN, engine information and any known repair history helps our team determine the correct configuration. Visit the Sinister Diesel Help Center to reach our team.