6.0L Power Stroke Engine and DrivetrainDiscussion of the 6.0L Power Stroke diesel engine and drivetrain in the 2003-Up Super Duties and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 6.0L Power Stroke engine.
If you're still under the 5 year/100K mile warranty, take it to the dealer and let them fix it. They'll likely replace the entire little manifold on the side of the HFCM (the part that has the drain plug in its cover), especially since you have a 2003 truck which was covered by a TSB to replace that part when the water in fuel light would go off erroneously due to crud buildup.
The new part should come with a steel plug instead of brass, which will fix the problem permanently. You can live with that, or do what a lot of us have done and upgrade to the knurled-knob plug as used in the LCF trucks sold by Ford and International.
The 1997 F250HD Crewcab: Picture
The 2000 XLT Excursion <font color="red">(SOLD)</font>: Picture
The 2003 F250 Crewcab 6.0L: Web page
The 6.0L Bible: Web page
The 6.4L Bible: Web page
I haven't had this problem. But someone once recommended JB Welding the allen wrench to the stripped plug head to get it out. Of course you would want to have the replacement plug ready to put in. I'm not sure if this will work, but it's an idea worth considering anyhow. Good luck.
2005 Arizona Beige F350 XLT FX4 6.0 CC shortbed, 3.73 ls rear, 18" wheels, Tow Command. Additions: Vent Visors, bug guard, Fumoto Valve, Timbrens. Traded for...
Current Truck -- 2008 Black F350 XLT 4x4, 6.8 V10, CC Long Bed, 4.10 rear, 18" wheels, IBC. Additions: Chrome Step Bars, Chrome door handles, Silver barbed-wire pin stripe, B&W Turnover GN ball
If the dealer won't fix free, you can use a center punch and hammer to remove it. Put center punch near outer diameter and start hitting with the hammer. Once it starts to dig in angle the punch so that it will loosen the plug and continue hitting it until it breaks it loose.
You might also try using the ball end of a ball peen hammer to hit the hex on the plug, this will flare some metal back into the hole and tighten the hex back up, then put your allen wrench back in and hit the allen wrench while trying to turn it.
These are old machinist / mechanic tricks that have worked for me in similar situations.
2006 2500 SLT Mineral Grey, 6 speed, 4x4, Thunder Road Package, MBRP Muffler + 6" dual Stacks, Fast Idle Enabled. Silencer Ring MIA, CFM+ intake horn, Smarty POD, SB Con OFe.
Traded:2004 F250CC FX4 XLT Long Bed Torque Shift, $5.00 AIC.
Of note here, after you get it fixed. The seal is accomplished by the o-ring, not torque. Just be really carefull when inserting the plug and only use mild force when torquing the wrench,
Kentucky built 2004 Silver F-250 XL Reg Cab PSD, 4X2, bench cloth seat,air conditioning, 6 spd Manual, 3.73 LS,Line-X , FORD receiver, Prodigy brake controller,towing option,( put together on Monday, March 29, del April 9 2004) 62000 miles