Did Ford make a 6.0 in 2002?

No. Ford did not release a 6.0‑liter engine in the 2002 model year; the 6.0‑liter Power Stroke diesel debuted for Ford’s Super Duty lineup in 2003.

To understand this, it helps to look at Ford’s heavy‑duty diesel lineup around the turn of the century and how the 6.0L fit into the broader timeline. The early 2000s were a period of transition as Ford moved from the 7.3L Power Stroke to a newer 6.0L variant, with reliability patterns that influenced buyer opinions for years to come.

Context: Ford's heavy‑duty diesel timeline

The Ford Super Duty pickups used a sequence of large, turbocharged diesel engines. The 7.3L Power Stroke served as the primary turbodiesel for much of the 1990s into the early 2000s, followed by the 6.0L Power Stroke as the next generation starting in 2003.

What happened around 2002–2003

In the 2003 model year, Ford introduced the 6.0L Power Stroke V8 turbodiesel to replace the 7.3L for the Super Duty lineup. This marked a shift in engineering, emissions compliance, and maintenance considerations that would shape ownership experiences in the years that followed. The 7.3L remained the longstanding predecessor, widely regarded for its reliability, while the 6.0L would become known for a set of mechanical issues that prompted updates and service bulletins over its production run.

Key engines in Ford’s Super Duty diesel era (relevant years explained):

• 1994–2003: 7.3L Power Stroke V8 turbodiesel (Ford-Navistar collaboration) — the prior generation used up through the early 2000s, overlapping with 2003 model year builds.


• 2003–2007: 6.0L Power Stroke V8 turbodiesel — introduced to replace the 7.3L, with notable reliability concerns that led to various fixes and recalls.

Conclusion: The 6.0L did not exist in 2002; Ford’s 2002 model year fleet was powered by the prior 7.3L engine, and the 6.0L entered the market in 2003.

Technical notes about the 6.0L introduction

The 6.0L Power Stroke was developed and produced as part of Ford’s strategy to modernize its diesel lineup. It was sourced from Navistar and installed in the Super Duty F-250 and F-350 trucks. The engine introduced several design changes but also carried a reputation for certain reliability challenges, particularly in the 2003–2005 window, which led to substantial maintenance considerations for owners and fleets.

• Introduced for the 2003 model year as the new Power Stroke diesel for Ford Super Duty pickups.


• Produced in a collaboration with Navistar International (the engine family is often referred to as a Navistar‑based 6.0L).


• Common issues included EGR cooler problems, oil cooler failures, head gasket concerns, and injector/monitoring system quirks that prompted updates and service bulletins from Ford.

Conclusion: If you’re evaluating a used Ford Super Duty from the early 2000s, the 7.3L (1994–2003) is typically viewed as the more robust choice, while the 6.0L (2003–2007) requires careful maintenance history knowledge and may benefit from known reliability updates and preventative fixes.

Summary

The concise answer to the question is no: Ford did not produce a 6.0‑liter engine in 2002. The 6.0‑liter Power Stroke was introduced for the 2003 model year to replace the 7.3L, and it remained in production through 2007, with a reputation for certain reliability issues that influenced ownership experiences. The 7.3L served as the main diesel option through the 2002 model year and into early 2003 builds.

In the broader timeline of Ford’s heavy‑duty diesels, 2002 sits between the era of the reliable 7.3L and the later 6.0L transition, a period that ultimately shaped consumer confidence and maintenance priorities for Ford’s diesel lineup in the following years.

What year to avoid a 6.0 Power Stroke?

The 6.0L Powerstroke engine years to be most cautious about are 2003-2004, as these early models had the most significant issues with high-pressure oil pumps, injectors, and head gaskets. While all 6.0L engines (2003-2007) are known for common problems like issues with the EGR cooler, oil cooler, and head bolts, the later model years 2005-2007 are generally considered improved and more reliable due to factory upgrades. 
Years to be most cautious (avoid if possible) 

• 2003-2004: These are the most problematic years due to a less reliable High-Pressure Oil Pump (HPOP), faulty injectors, and a higher susceptibility to head gasket failure due to weaker head bolts. 

Years with factory improvements 

• 2005-2007: These years incorporated numerous factory updates, making them more reliable. Key improvements include an updated HPOP, upgraded head bolts (20mm vs. 18mm), and a better engine oil cooler design, though they can still experience issues, particularly with oil leaks from dummy plugs and standpipes. 

What to do if considering any 6.0L Powerstroke

• Look for "bulletproofed" trucks: A truck with all the common weak points addressed through aftermarket "bulletproofing" can be a great purchase. Be sure to ask for proof of the work performed. 
• Factor in repair costs: All 6.0L engines will likely require some repairs, so be prepared for potential costs for things like EGR and oil coolers, head studs, and turbo/HPOP issues, regardless of the model year. 

How many miles will a bulletproofed 6.0 last?

A "bulletproofed" 6.0L Powerstroke engine can last anywhere from 350,000 to 500,000 miles or more with proper maintenance, proper installation of upgrades, and good driving habits. "Bulletproofing" refers to a set of modifications to fix common issues, but the lifespan ultimately depends on the quality of the work, regular maintenance, and how the truck is used. 
Factors that determine longevity

• Quality of bulletproofing: The effectiveness of the modifications is a major factor. A professional, comprehensive "bulletproofing" that addresses the most common failure points is crucial for achieving high mileage. 
• Maintenance: Consistent and proper maintenance, including checking fluids and following the recommended oil change schedule, is essential. Regular maintenance can prevent problems before they become major. 
• Driving habits: Frequent and hard towing, constant high-RPM driving, or "hotrodding" can put extra strain on the engine and reduce its lifespan. 
• Tuning and fuel quality: Aggressive tunes and poor-quality fuel can negatively impact the engine's longevity. Opting for a conservative tune and using quality fuel is a better approach for a daily-driven or long-life build. 
• Model year: The 2005-2007 models are generally considered the most reliable, as they had several factory upgrades before the 6.0L was phased out. 

What "bulletproofing" includes

• Head Studs: These replace the factory head bolts, which are prone to stretching and failing, causing head gasket leaks. 
• EGR Cooler Upgrade: The factory EGR cooler is a common failure point. An upgraded, more robust EGR cooler is a key part of a successful "bulletproof" package. 
• Cooling upgrades: Improving the cooling system, which includes the oil cooler, is vital for preventing overheating issues. 
• Standpipes and Dummy Plugs: These are often replaced as part of a comprehensive rebuild to prevent oil leaks. 
• Oil and Fuel Filtration: Adding or upgrading the fuel and oil filtration systems can help protect the engine from contaminants. 

Does Ford make a 6.0 gas engine?

No, Ford does not make a 6.0-liter gasoline engine; the 6.0L in Ford's lineup has always been a diesel engine, specifically the 6.0L Power Stroke. This diesel engine was produced from 2003 to 2007 and is known for its V8 configuration, but it is not a gas engine. It is common for people to confuse it with GM's 6.0L Vortec gas engine, or for a Ford truck owner to be misinformed about their vehicle's engine.
 

• Engine type: The 6.0L is a diesel engine, not a gasoline engine. 
• Vehicle application: It was used in Ford Super Duty trucks, the Excursion, and E-Series vans during its production years. 
• Distinction from GM: It is often confused with GM's 6.0L Vortec gasoline engine. 

What year of the 6.0 Power Stroke is the best?

The 6.0s have a very bad reputation and the early '03s really deserve it with poor high pressure pumps, bad injectors, and head gasket problems. But Ford Motor Company and International made upgrades to this engine over time that made the '05-'07s really good trucks.