Diesel Sales Reference ManualFOR ALL FORD POWER STROKE DIESEL ENGINES

Diesel Sales Reference Manual

For All Ford Power Stroke Diesel Engines

www.PowerStrokeDiesel.comwww.FordParts.com

DSLSALESREFMAN 01-15 35M © 2015 Ford Motor Company, Dearborn, MI

All material in this literature is as accurate as known at the time of publication, but is subject to change without notice. Ford, Power Stroke® Diesel, Ford Parts Warranty, Ford Parts and Motorcraft logos are registered trademarks of Ford Motor Company.

ENGINES

COMPONENTS MAINTENANCE PRODUCTS

2014_DSRM_Cover_PROD.indd 1-3 1/25/15 8:19 PM

See your Ford or Lincoln Dealership or Ford Authorized Distributor for additional details

Includes Labor*

NO Commercial Exceptions!!

2-Years/ UNLIMITED Miles

NEW Service Part Warranty on

Ford Genuine & Motorcraft Parts

*Labor may have a limit. See your seller for a copy of the limited warranty.

© 2015 Ford Motor Company 1

TABLE OF CONTENTS

How to Use this Manual 2-3

Applications - V8 4-406.7L F-250/F-550 4-6

6.4L F-250/F-550 7-8

6.0L F-250/F-550 9-12

6.0L F-650/F-750 13-15

6.0L Excursion 16-19

6.0L E Series 19-21

7.3L DIT F-250/F-550 22-25

7.3L DIT F-650/F-750 26-27

7.3L DIT Excursion 28-29

7.3L DIT E Series 30-32

7.3L IDIT F-250/F-350 33-34

7.3L IDI F-250/F-350 34-35

7.3L IDI E Series 36-37

6.9L IDI F-250/F-350 37-38

6.9L IDI E Series 39-40

Applications - V6 40-424.5L LCF 40-42

Applications - I5 42-433.2L Transit 42-43

Illustrations 44-108Engines 45-50

Engine Overhaul Kits 51-53

Engine Components 54-88

Sensors 89-94

Maintenance 95-108

Cross Reference 109-122

Part Number Index 123-128

Appendix 129-152Remanufactured Diesel Engines 130-136

Engine Overhaul Kits 137

Engine Components 138-141

Maintenance 144-152

© 2015 Ford Motor Company2

HOW TO USE THIS MANUAL

The Diesel Sales Reference Manual delivers: 1) Simplified part number identification for selling Ford remanufactured diesel parts and engine assemblies 2) Key selling features and benefits for the Ford brand of replacement diesels 3) 100% core credit return policy information 4) Part number cross references and a part number page index

How to use this manual:This manual answers most questions about replacements for diesel engines used in Ford Motor Company vehicles. Properly identifying replacement part numbers begins with identifying the vehicle and engine using one of the following two methods:

Finding the Ford service part (assembly) number used to replace an original engine begins with retrieving the production engine ID number from the calibration label located on the oil reservoir (94-95 MY) or on the left valve cover (96 MY to 2003) for 7.3L engines. The calibration label is located on the Fuel Injection Control Module (FICM) for 6.0L engines 2003 to 2007, and on the Vertical EGR Cooler for the 6.4L engine 2008-2010. The production engine ID number or tag number is the large 7-digit number at the top center of the label. Record the seven digit production engine ID number.

Example: 5G 001 AARefer to the Engine ID Number Cross Reference Section (beginning on page 112 of this manual) and locate the production engine part number. The correct replacement service part number will be listed in the column labeled Ford Service #. All remanufactured replacement engines, components and parts are grouped in trim levels in this section. In the 5G 001 AA example, if you chose to replace the complete running engine assembly (6007) you would select Ford Service Part Number F4TZ-6V007-FARM.

Tag NumberMETHOD 1

METHOD 2This alternate process is also reliable. Begin by retrieving the engine serial number. See next page for engine serial number locations.

Next, make the appropriate selections from the Applications Section (beginning page 4) Make the following selections:

Select page for engine and model of truck: LCF, F Series, Excursion or E Series

Select engine level of service from the Application column, e.g. engine Short Block (6009), engine Long Block (6006 or 6012), engine Complete (6007), etc.

Select application and model year from the two appropriate columns, e.g.1996 E-350 California

Verify engine serial number from the Engine Serial Number Breaks column*

© 2015 Ford Motor Company 3

HOW TO USE THIS MANUAL

METHOD 2 (continued) 6

.0L

6.0

L

Left Rear Corner Crankcase Fuel Injection Control Module

Top Front on Flat Embossed Area

6.9

L, 7

.3L

IDI

& 7

.3L

IDIT

7.3

L DI

T

Left Rear Oil Cooler Base

6.4

L

6.4

L

Left Rear Corner Crankcase Vertical EGR Cooler

In the example of a 1996 7.3L E-350 California with engine serial number 301,001, the correct choice of replacement assembly numbers for a engine-long block (6006) would be F6UZ-6V006-AARM.

* When verifying 6.0L serial numbers, look at the entire serial number to determine build origin. If the sixth digit is the letter Y, then the engine was built in Huntsville, AL and the serial number ends in a range of 0-94,580 for 2003 and 137,745-current for engines built after 2003. If the engine serial number ends within the 6,000,000 series and the sixth digit is the lettter U, then the engine was built in Indianapolis, IN.