Just like our 7.3 recall list, on this 6.0L recall list, we’ll concentrate on drivetrain related recalls and include links to documents where we can find them. Some recalls listed on the NHTSA site have missing paperwork or dead links—assumably because: the campaign was handled prior to owners taking delivery, it was handled quietly at the dealer level, or the documentation simply didn’t survive the internet. Also, keep in mind that while the 6.0L had many commonly known issues, Ford did not officially issue recalls for many of them. There are countless TSB’s related to the platform, and some issues were delt with in other ways, such as by reimbursing owners for certain repairs done. These are not officially recalls and therefore are not listed here.

This list applies to 6.0L-equipped vehicles, but each recall won’t apply to every year/model. For every entry, we’ll include the control number (NHTSA and/or Ford) so you can dig deeper if you want. If you’re trying to figure out whether your truck is affected right now, run your VIN through NHTSA’s recall lookup—then call a Ford dealer with the campaign number if it shows as open.

NHTSA Recall Checker: https://www.nhtsa.gov/recalls

Note: We’re not going to clutter this up with parts-supplier recalls that don’t meaningfully apply to current owners. If we missed one you think belongs here, email us and we’ll add it.

 

 

04V-327 / Ford recall 04S15 — Engine ground stud (fire risk)

What/why: The engine ground attachment/ground stud may be loose, which can force current through an unintended path (radio suppression strap), potentially causing overheating/smoke/fire.

Vehicles: 2003 MY F-250 through F-550 and 2003 Excursion equipped with the 6.0L diesel, built at KTP 12/1/2002–3/31/2003.

Remedy: Replace the engine ground stud and inspect/replace the radio suppression strap/adjacent components as needed.

Document: https://static.nhtsa.gov/odi/rcl/2004/RCDNN-04V327-2989.pdf

 

 

05V-270 / Ford recall 05S34 — Engine stalling (FICM harness / ICP connector)

What/why: Certain 6.0L trucks/vans may stall without warning due to wiring-related issues involving the Fuel Injection Control Module (FICM) harness and/or the Injection Control Pressure (ICP) sensor connector.

Vehicles: NHTSA lists E350/E450 (2004–2005), Excursion (2004–2005), and F-250/F-350/F-450/F-550 Super Duty (2004–2005) under this campaign.

Remedy: Upgrade/replace FICM harness and/or install a new ICP sensor connector.

Document: https://static.nhtsa.gov/odi/inv/2005/INCR-EA05003-23050P.pdf

 

 

03E03 — PCM + FICM recalibration (California-certified vehicles)

What/why: Powertrain Control Module (PCM) and Fuel Injector Control Module (FICM) recalibration (emissions/driveability related) for certain CA-certified 6.0L applications.

Vehicles: Listed as affecting 2003–2004 6.0L diesel Super Duty/Excursion in California-certified configurations (sources vary on exact coverage details).

Remedy: Reflash PCM and FICM with new software

Documents Unavailable

 

05E15 — Exhaust Pressure (EP) sensor replacement + OBD/engine control modules recalibration (Voluntary Emission Recall)

What/why: On some affected vehicles, corrosion at the EP sensor electrode surface, non-optimal cold-weather fueling timing, and/or non-optimal EGR operation at idle can trigger “Check Engine” light illumination, lack of power, hard starting, and/or rough engine operation. Ford also notes the OBD system may not properly monitor emission control system performance on some vehicles.

Vehicles: Certain 2004–2005 model year F-250/F-350/F-450/F-550, Excursion, and E-350/E-450 vehicles equipped with the 6.0L, with eligibility determined by specific build-date/VIN ranges (Ford directs dealers to verify in OASIS).

Remedy: At no charge (important becasue this one's voluntary), dealers replace the EP sensor (and on some build groups, the EP connector) and recalibrate/reflash the engine control modules to the latest software (Ford references reprogramming PCM/TCM/FICM as applicable).

Document: https://static.nhtsa.gov/odi/rcl/2005/RCRIT-05V270-2396.PDF

 

 

05E16 — Engine control modules recalibration (Voluntary Emission Recall)

What/why: On some affected vehicles, the on-board diagnostic (OBD) system may not properly monitor emissions-control system performance, which can prevent the required “check engine” light illumination.

Vehicles: Certain 2004–2006 F-250/F-350, Excursion, and E-350 vehicles equipped with the 6.0L diesel (Ford breaks coverage into groups/build ranges; examples called out in the dealer letter include 2005–2006 E-350 (built 3/4/2005–8/7/2005), 2005 Excursion (built 1/19/2005–9/30/2005), and 2005–2006 F-250/F-350 (built 1/19/2005–7/31/2005), plus a smaller group of certain 2004 builds tied to earlier incomplete calibration work).

Remedy: Dealer will recalibrate (reflash) the engine control modules with the latest software to enhance OBD function; the procedure updates the PCM, TCM, and FICM using Ford’s diagnostic programming process.

Documents Unavailable

 

06E17 — Control module recalibration (EP sensor/EGR/driveability/OBD monitoring)

What/why: Addresses issues such as EP sensor electrode corrosion, cold-weather fueling timing, and/or EGR operation at idle, which can cause check engine light, lack of power, hard start, rough running, and OBD monitoring concerns.

Vehicles: 2003–2004 F-250/350/450/550 and Excursion with 6.0L diesel built Job #1 2003 through 9/28/2003 (per the bulletin).

Remedy: Reflash engine, transmission, and fuel injection control modules; the update can deactivate EP sensor input and infer exhaust pressure instead.

Document Unavailable

 

09V-399 (Ford recall 09S09) See also 07V-078 (Ford recall 05S28 supplement for the later model trucks) — SCDS internal leak → overheating / vehicle fire

What/why: Vehicles equipped with the Texas Instruments SCDS may have the switch leak internally, then overheat, smoke, or burn, which can lead to a vehicle fire with or without the engine running.

Vehicles: Includes 2000–2003 Excursion (diesel) and 1999–2003 F-250 Super Duty through F-550 Super Duty (diesel) (plus other Ford lines/years outside your target window).

Remedy: Install a fused wiring harness in-line with the SCDS (Windstar has an additional ABS connector inspection step, but that’s not relevant to Super Duty/Excursion). Repair is free of charge.

Document Unavailable

 

11V-352 (Ford recall 10C18) — Steering column multifunction switch may fail (lighting functions inop)

What/why: A replacement multifunction switch (turn-signal/lighting stalk switch) was shipped with a subcomponent (“slider”) that can deform, causing the switch to malfunction—potentially resulting in turn signals, tail lights, hazards, and/or brake lights not activating (FMVSS 108 noncompliance).

Vehicles: Coverage language includes 2002–2005 Excursion and 2002–2007 F-250/F-350/F-450/F-550 (this campaign is largely about service parts distributed to dealers that may have been installed on those vehicles).

Remedy: Dealers replace the affected multifunction switch free of charge (Ford’s campaign number shown as 10C18 in the NHTSA letter).

Document Unavailable

 

 

 

Disclaimer: The information provided on this blog is for informational purposes only. We share our knowledge and experience, but we are not liable for any damages, injuries, or losses that may occur as a result of using this information. Situations are rarely cut and dry in the automotive world. Your situation will likely be somewhat different than what we describe here. Use your best judgment and always consult a qualified professional for automotive repairs and modifications. Your safety is your responsibility.