The Driven Diesel DD-60FS-BanjoKit-2 High-Flow Banjo Bolt Kit is a precision-engineered performance upgrade designed specifically for the front cylinder head fuel inlet ports on 2003–2007 Ford Super Duty trucks and Excursions equipped with the 6.0L Powerstroke diesel engine. Precision CNC-machined from corrosion-proof T-303 stainless steel, this 2-piece kit eliminates the severe factory fuel line restrictions and internal check-valve turbulence, delivering increased, uninterrupted fuel volume directly to the front fuel injectors.

Quick Specs & Kit Inclusions

• Application: Front cylinder head fuel rail inlet banjo ports
• Material Construction: CNC-machined T-303 stainless steel for lifetime durability and rust prevention
• Flow Geometry: Features an enlarged central bore, oversized chamfered cross-drilled side passages, and an undercut base profile
• Internal Check Valve: 100% check-valve-free, open-flow design to eliminate fuel pulsation turbulence
• Emissions Status: 50-state legal (CARB compliant direct replacement part; does not alter PCM fuel tables or injection timing)
• What's in the Box: (2) Driven Diesel T-303 Stainless Steel High-Flow Banjo Bolts and (4) Annealed Copper Sealing Washers

Problem Solved: Eliminating Banjo Restriction, Turbulence & Fuel Starvation

The original equipment Ford banjo bolts installed in the front of the 6.0L Powerstroke cylinder heads incorporate internal check valves and restrictive, undersized fuel metering passages. These factory check valves cause significant hydraulic turbulence and drop-offs in dynamic fuel volume right at the cylinder head entrance. When demanding full power, pulling heavy trailers, or running performance calibrations and upgraded injectors, these bottlenecks restrict fuel supply to injectors #1 and #2. The resulting fuel pressure drops can induce injector cavitation, rough engine idle, audible fuel knock, and premature intensifier piston wear. The Driven Diesel DD-60FS-BanjoKit-2 removes the restrictive internal check balls and dramatically expands cross-sectional flow area, stabilizing fuel pressure and smoothing delivery across the entire cylinder head rail.

Fitment

• 2003.5–2007 Ford F-250 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003.5–2007 Ford F-350 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003.5–2007 Ford F-450 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003.5–2007 Ford F-550 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003.5–2005 Ford Excursion 6.0L Powerstroke Turbo Diesel
• Fitment Note: Services the two front cylinder head fuel supply ports on standard factory fuel line systems. (Note: These banjo bolts are already included in the full Driven Diesel 6.0L Regulated Return kit).

Safety & Depressurization: Park on level ground, turn off the ignition, and disconnect both negative battery cables. Slowly loosen the secondary fuel filter cap (24mm or 15/16" socket) on top of the engine valley fuel bowl to bleed off residual head pressure and allow fuel to drain down. Access Preparation: Gain access to the front of each cylinder head. On the driver side, loosening the CAC (intercooler) pipe or moving wiring harness loom brackets will provide direct line-of-sight to the fuel banjo fitting. Place absorbent shop towels beneath both front cylinder head ports to catch fuel spillage. Factory Banjo Bolt Removal: Using a socket or line wrench, unthread the factory front banjo bolts counter-clockwise. Carefully remove each bolt along with its upper and lower factory crush washers. Discard the old washers. Port & Mating Surface Cleaning: Wipe the cylinder head female M12x1.5 threaded ports and both sides of the factory fuel tube banjo rings with a lint-free cloth and brake cleaner. Ensure no dirt, debris, or old copper fragments remain on the sealing faces. Washer & Bolt Assembly: Slide one (1) new annealed copper washer onto each Driven Diesel stainless steel banjo bolt. Insert the bolt through the factory fuel line banjo eyelet, then slide the second (2nd) copper washer onto the bolt threads so the fuel line fitting is sandwiched between the two washers. Thread Engagement: Carefully hand-thread each banjo bolt into the front cylinder head port several turns to confirm smooth, square thread engagement. (Never use an impact or wrench to start the threads into the cylinder head). Torque Target: Hold the fuel line steady to prevent the metal tube from twisting or binding against engine brackets during final tightening. Using a calibrated torque wrench, tighten each banjo bolt to 20 ft-lbs (27 Nm). Do not over-tighten, as excessive torque will crush the copper washers excessively or distort the banjo fitting. Priming & Leak Verification: Reconnect the negative battery cables and tighten the secondary fuel filter cap to 19 ft-lbs (25 Nm). Turn the ignition key to the "RUN" position for 30 seconds without cranking the starter to allow the electric fuel pump to prime the rails and bleed out air. Repeat the key cycle 3 to 4 times. Carefully inspect both front banjo fittings for any signs of fuel seepage before starting the truck.