The 6.0 Powerstroke Injector was introduced by Ford Trucks in 2003 when there was an urgent need to replace the 7.3L high emissions. Although the 6.0 has had a rocky start and has undergone various difficulties, it was considered to be groundbreaking engineering. The 6.0L Power Stroke provided an exhaust gas recirculation system as well as a more advanced and second generation fuel injection system, until problems begin to arise.
The Powerstroke 6.0L injector was designed to meet the guidelines for cleaner and more efficient burning with a diesel engine. The 6.0L offered better performance and better fuel mileage. Ford pressured International to quickly get the changes made for their 2003 truck engines, which resulted in a variety of problems, including problems with the software in the first engines off of the line, which created problems in the injection system. This resulted in unreliable emergency vehicles that had the new 6.0L and several lawsuits filed against the Ford Motor Company. It was found that technicians were not correctly trained for working on the new engines, so they could not adequately solve problems that came up with the engine.
Drivers and owners began experiencing problems with the emissions system, in that the exhaust system was not recirculation properly, which caused clogging and the system to run too hot. Overtime the clogging and overheated system caused larger problems such as head gasket failure. It was concluded that these problems were the result of poor planning. The idea for the 6.0L Power Stroke was based on the International VT365, but it was designed for light to medium size trucks, such as delivery trucks and passenger vans. Light duty and heavy duty engines have different emissions standards, which were taken into account during the development of the 6.0L Power Stroke.
There were a number of lawsuits filed against the Ford Motor Company and International for the 6.0L Power Stroke, but Navistar, a division of International, took the brunt of lemon law filings and lawsuits. Eventually the Ford Motor Company and International parted ways. Lemon laws continue to allow dealerships to make repairs on the engine a specific number of times, but then the manufacturer has to take the vehicle back, so Ford is continuing to deal with problems from the 6.0L. Ford no longer provides an in-house manufacturing of Power Stroke diesel engines as a result of their lessons learned.