Ford 6.0L Powerstroke Thermostat Replacement

How to replace the thermostat on a 6.0L Ford Powerstroke diesel engine. Ensure that all of the air is bled out of the cooling system after replacement.


Let’s take a look at the process, in which we’re gonna replace the thermostat on this Ford truck with a 6.0L Powerstroke diesel engine.

Now we’re in here doing some other work already, so the radiator is actually removed, the fan shroud is out of the way, so it’s going to look a little bit more open than it is, but this is really a pretty straightforward job. We’ve also removed the charge air cooler tube here as well, set that off to the side. If you want to do that, that’s not that difficult. A couple 12 mm bolts to loosen the clamps here. Set it off to the side. Then we can get at the thermostat housing here. Now, first there’s a bracket holding the exhaust back pressure sensor in place. We’re going to back those nuts off, and then we’re gonna remove these two studs up out of the upper cover here, and that will remove our whole housing along with the thermostat. This is a one-piece unit here.

So let’s go ahead and start removing these nuts and bolts. I’ve actually gone ahead and removed the upper radiator hose to make it a little easier for you to see here. I’m just gonna take my 13 mm ratchet and socket and loosen this up, and you can see that bracket for the exhaust back pressure sensor is ready to pop up off here, so we’ll get that up out of the way. Gently set that off to the side. I’m gonna need a deep socket here and we’ll remove these two bolts and pull the unit up out of there. Now we’ve got our old unit out, and make sure that the o-ring comes up with it, our new one comes with an o-ring installed already so we’re going to clean up the mating surface and reinstall this, torque it down in place, we’re going to bolt that bracket up, reassemble everything, and we will bleed and fill our cooling system, and we’re ready to go.

Hopefully now you understand what it takes to replace the thermostat on a 6.0L Powerstroke engine.