The Driven Diesel DD-60FS-FBD-RRK-V3 Fuel Bowl Delete Regulated Return Kit is a complete high-performance fuel delivery system engineered specifically for 2003–2007 Ford Super Duty trucks and Excursions equipped with the 6.0L Powerstroke diesel engine. Combining the unrestricted flow of an engine-valley fuel bowl delete with the hydraulic stability of a full parallel regulated return, this Version 3 kit eliminates the factory dead-headed fuel rails and restrictive secondary filter bowl. It feeds fuel directly into the front cylinder head ports and routes return fuel out the rear ports through a premium Fuelab bypass regulator, stabilizing rail pressure, purging trapped air, and maximizing HEUI injector service life.

Quick Specs & Kit Inclusions

• System Architecture: Complete parallel-loop regulated return integrated with secondary fuel bowl delete distribution block
• Regulator: Premium Fuelab billet aluminum adjustable bypass fuel pressure regulator
• Hard Lines & Hoses: CNC-bent stainless steel rigid hard lines in tight radius/high-heat locations combined with 3/8" stainless steel braided Teflon hoses with black protective sleeves
• Distribution Block: CNC-machined billet aluminum fuel bowl delete distribution block
• Manifold Clearance: V3 architecture engineered to clear stock intake manifolds as well as aftermarket performance manifolds (including Odawg S2 and S3)
• System Monitoring: Includes a Driven Diesel liquid-filled 0–100 PSI mechanical fuel pressure gauge
• Bracketry: Custom T-304 stainless steel alternator-mount regulator bracket
• Emissions Certification: CARB Approved (CARB EO# D-872-2 for 2003–2007 F-250/F-350 and Excursion)
• Direct Interchange Part Numbers: Driven Diesel DD-60FS-FBD-RRK-V3, DD-60FS-FBD-RRK
• What's in the Box: (1) Fuelab Adjustable Bypass Regulator, (1) Driven Diesel Liquid-Filled Pressure Gauge, (1) CNC Fuel Bowl Delete Block, (1) T-304 SS Regulator Bracket, (1) Complete Set of SS Hard Lines & Braided Teflon Hoses, AN Fittings, Hardware, and Full-Color Instructions

Problem Solved: Curing Dead-Head Starvation, Aeration & Engine Valley Bottlenecks

In factory trim, the 6.0L Powerstroke feeds fuel into the front of each cylinder head with no exit path except through the injector nozzles. This "dead-headed" configuration traps heat and aerated fuel at the back of the cylinder heads, causing severe pressure drops at rear injectors #7 and #8 under heavy load, towing, or aggressive tuning. Sub-45 PSI pressure drops trigger fuel cavitation, eliminating the liquid cushion that protects the HEUI intensifier pistons and leading to injector failure, spool valve stiction, and rough idle. Furthermore, retaining the factory plastic secondary fuel bowl introduces leak-prone cap threads, standpipe failures, and tight valley clutter. The Driven Diesel DD-60FS-FBD-RRK-V3 solves both problems in a single package: it removes the failure-prone valley bowl, establishes a continuous fuel loop that routes trapped air back to the tank, and maintains rock-solid, user-adjustable fuel pressure across all eight injectors.

Fitment

• 2003–2007 Ford F-250 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-350 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-450 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-550 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2005 Ford Excursion 6.0L Powerstroke Turbo Diesel
• Critical Installation Requirements:
  • Chassis Filtration Required: Because the factory secondary fuel bowl is removed, you must have an external chassis-mounted secondary fuel filter (2-micron absolute rating) and lift pump system installed (such as a FASS Titanium, AirDog II-5G, or Driven Diesel Post-Pump filtration setup). This kit is not compatible with the stock lift pump.
  • Oil Filter Housing: The stock oil/fuel filter bowl assembly must either have the fuel bowl portion cut off or be replaced with an OE standalone oil filter bowl.
  • Alternator Compatibility: The regulator bracket mounts directly to factory-style alternators; some large-case/high-amp aftermarket alternators require custom bracket clearance.
  • Platform Note: Does not fit Ford Econoline E-Series vans.

Safety & Depressurization: Park on level ground, engage the parking brake, and disconnect both negative battery cables. Ensure the engine valley is completely cool, and relieve any residual pressure in the supply system. Component Teardown & Valley Clearing: Remove the intake ducting, upper intercooler (CAC) tubes, and alternator mounting bolts as required for access. Disconnect factory fuel supply and head feed lines. Unbolt and remove the factory secondary fuel filter bowl assembly from the valley. Prepare the oil filter bowl (install a standalone oil filter housing or trim the unneeded fuel bowl section). Delete Block Mounting: Mount the Driven Diesel CNC-machined fuel distribution block securely in the engine valley using the supplied mounting hardware and brackets. Cylinder Head Plumbing: Front Inlet Ports: Install the CNC-bent stainless steel front supply hard lines and high-flow banjo/AN adapters into the front cylinder head ports, torqueing to 20 ft-lbs (27 Nm). Rear Outlet Ports: Remove the square-drive pipe plugs from the rear fuel rail ports on both cylinder heads. Thread the supplied AN adapter fittings into each rear port, ensuring clean, sealed threads. Regulator & Line Routing: Mount the T-304 stainless bracket and Fuelab bypass regulator to the alternator location. Connect the black-sleeved stainless braided lines from the rear head ports to the regulator inlet ports. Plumb the regulator return outlet back to the chassis fuel tank return line. Connect the supply line from the chassis lift pump directly to the valley distribution block. Gauge Installation: Thread the Driven Diesel liquid-filled 0–100 PSI gauge into the dedicated 1/8" NPT port on the Fuelab regulator using PTFE thread sealant paste. AN Fitting Torque: Snug and torque all AN swivel line ends using an aluminum AN service wrench to 15–18 ft-lbs (20–24 Nm). Priming, Pressure Calibration & Leak Verification: Reconnect the battery terminals. Key on (KOEO) to run your external lift pump and bleed air out of the distribution block and rails. Loosen the locknut on the top of the Fuelab regulator and adjust the set screw until running fuel pressure stabilizes at 60–65 PSI. Tighten the locknut to lock in the setting. Thoroughly check all valley ports, head fittings, and hose connections for zero fuel weeping before starting the engine.