6.0 Powerstroke New Billet Stage 2 HPOP

6.0 Powerstroke New Billet Stage 2 HPOP | Atlas 477-7590 (2003–Early 2004)

Upgrade the most common failure point on early 6.0L Powerstrokes with a true billet Stage 2 high-pressure oil pump.

The Atlas 477-7590 New Billet Stage 2 HPOP is built specifically for 2003–early 2004 6.0L Powerstroke engines (round-style pump). It delivers the reliability and extra oil volume that stock and remanufactured pumps simply can’t match.

Why Choose the Atlas New Billet Stage 2?

Early 6.0L HPOPs are notorious for housing wear, loss of pressure, and outright failure — especially when paired with larger injectors or performance tunes. The Atlas solves this with a new billet aluminum housing machined from solid billet for maximum strength and durability. This eliminates the weak points found in factory aluminum castings.

Inside, the pump is engineered as a true Stage 2 unit, producing 25–30% more flow than a stock OE HPOP. This extra volume helps maintain strong Injection Control Pressure (ICP) under load, giving you:

Quicker, more consistent starts
Smoother and more precise injector actuation
Better throttle response
The ability to support larger injectors (typically up to ~225cc) without starving the HEUI system

Whether you’re running stock injectors and want rock-solid reliability or building a higher-horsepower truck, this pump gives you headroom for future upgrades.

Key Features & Benefits

New billet aluminum housing — Superior strength and longevity vs. stock or reman castings
25–30% more flow than stock OE HPOP
Supports injectors up to approximately 225cc
Includes O-ring install kit for a complete, leak-free installation
Direct-fit replacement for 2003 – early 2004 6.0L Powerstroke (F-Series & Excursion)
Replaces OEM part numbers: 1838828C91, 3C3Z-9A543-AARM, 4C3Z-9A543-AARM
1-year warranty

Perfect For

Fixing or preventing common early 6.0 HPOP failures
Trucks with upgraded injectors (up to ~225cc)
Daily drivers, tow rigs, or performance builds that need reliable high-pressure oil delivery
Anyone who wants a new pump (not remanufactured) with a stronger housing

Note: This is the new billet version (477-7590). It is designed for 2003–early 2004 engines only. Late 2004.5–2007 models use a different-style HPOP.

Includes: New billet Stage 2 HPOP + O-ring install kit Core charge applies (refundable upon return of your old pump) Warranty: 1 Year

Give your 6.0L the high-pressure oil supply it deserves. The Atlas New Billet Stage 2 HPOP is the premium choice for reliability and performance on early 6.0 Powerstrokes.

Stage 2 hpop

Max (Illinois) | September 17th, 2024

Install was straightforward pump came ready to rock driven 500 miles without an issue and currently loving it would recommend at the price point

Verified Buyer

Stephen Beckwith (Colorado) | January 3rd, 2024

Pump arrived with poorly taped screws holes for the discharge pipe, supplied screws would bind about halfway into the hole. Unit had to be returned. Replacement unit also had the same issue even thought I ask the sales rep to verify the unit did not carry the same issue by checking the threads with the supplied screws prior to shipping the replacement. In the end I had to re-tap the holes myself - not what I expect on a $1000+ unit. Makes me think if they cant get the threading correct, who knows what the tolerance are like on the internals. I'm stuck with it now, but if I could do it again I would just get a remanufactured Motorcraft unit with 2-year warranty and save myself the headache. Full Force also did not refund my overnight shipping and charged me for the replacement unit which is crappy customer service when they sent out a defective item twice.

Billet stage 2

Jacob Welch (Edgewood) | October 14th, 2023

This pump has good history and reviews on the forums. I decided to give it a try with the bigger fuel setup. It definitely moves the oil and seems like a great HPOP so far. Fairly straight forward install and I am liking the pressure numbers it makes.

Enthusiast

Myke Patytskyy (Chicago, IL) | May 2nd, 2023

Wow!! What a pump, got the early 03 style motor configuration and already replaced the high pressure pump twice (with reman pumps from Bostec ((stay away))" ... this is my 3rd and hopefully final replacement. Bought for reliability, but was impressed by the slight performance gain also.Quicker starts, and injectors rev the motor up smoothly & sequentially vs the factory all at the same time violent bang style. This pump DOES produce more pressure, on stock injectors you can expect quicker revs. If I had to compare to household objects, this pump changed how my injectors actuate: it's like a sluggish wall clock tick (factory/reman) vs a defined rollex tick (this one right here).So yes, spend the extra money especially with our plagued early models. Engine sounds healthier than the day I bought it (190k miles ago).