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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.
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
<[...]
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.
Q
John wick • 05/22/2026, 0:55:45 AM
What type of warranty does this bad boy have?
A
05/22/2026, 2:35:38 PM
Warranty is noted on the product page as 1 year.
Q
Jacob • 06/27/2026, 4:54:56 AM
Like the idea of the billet housing without the ball that can fall out any issues running this on a stock injector truck?
A
06/29/2026, 1:14:44 PM
Fine for stock injectors.
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4/5 Stars out of 4 Reviews
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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.
Proposition 65 Warning Information -
P65Warnings.ca.gov
Fits: 6.0 Powerstroke 2003-2004.5
Fits: 6.0 Powerstroke 2003-2004
California Restricted
Fits: 6.0 Powerstroke 2003-2004