07/03/2025
CUSTOMER CONCERN:
This 2003 F-350 with the 6.0L Powerstroke came in with concerns of high oil temperatures, a loose downpipe, and a significant oil leak that needed to be identified.
DIAGNOSTICS & INSPECTION FINDINGS:
During diagnostics, we found that the exhaust had been knocked loose from the downpipe and required a new clamp. Additional findings included:
• Exhaust manifold leaks — we recommended replacing the manifolds and gaskets.
• Oil pan was severely rusted and seeping oil.
• Upper oil pan and camshaft position sensor seal were both leaking — replacement was recommended.
• Power balance test revealed that at least a couple of injectors were weak.
• Oil temperatures were observed to creep up during diagnostics — we recommended addressing the exhaust leaks first, and if the issue persists, replacing the oil cooler.
• The truck was equipped with stock head bolts — we recommended our comprehensive Solutions Package, which includes ARP head studs and a new oil cooler, while also covering the labor associated with the repairs above.
During our 18-point inspection, we also noted the following:
• Wiper blades were worn
• License plate bulbs were out
• Coolant level was low
• Cab mounts were deteriorated
• Tires needed rotation
• Tie rod at the Pitman arm had excessive play
APPROVED REPAIRS:
The customer approved our Solutions Package while choosing to retain the OEM cylinder heads (although we recommended Kill Devil Diesel Icon heads ). Additional approved items included:
• New windshield wipers
• New cab mounts
• New oil pan
• New fuel injectors
• Replacement of the driver-side valve cover
• One new exhaust manifold
• Tire rotation, balance, and alignment
FINAL STATUS:
All approved repairs were completed. The truck was test driven and returned to the customer in good running condition.