The Mahle 54204 is a standard-thickness OEM-replacement cylinder head gasket engineered for 1994–2003 7.3 Powerstroke diesel engines. Manufactured to rigorous factory equipment specifications by Mahle Original, this premium graphite cylinder head gasket incorporates reinforced steel combustion fire rings and elastomeric print seals to ensure dependable fluid control and combustion sealing across heavy cast iron decks.

Blown cylinder head gaskets, combustion gas pressurizing the degas bottle, coolant consumption, and oil or coolant leaks weeping down the side of the engine block are what this gasket solves. High mileage, intense thermal cycles from heavy hauling, and elevated cylinder pressures breakdown aged factory composite gaskets over time. Installing Mahle Original graphite head gaskets restores factory deck sealing integrity and provides the proper thermal compliance needed between the cast iron cylinder heads and engine block under load. It is sold as a single cylinder head gasket; two gaskets are required to complete an engine build, and cylinder head bolts or studs are sold separately.

It fits all 1994–2003 7.3 Powerstroke Ford Super Duty trucks, OBS F-Series, Excursions, and E-Series vans.

Fitment

• 1994–1997 Ford F-250 / F-350 OBS 7.3L Powerstroke
• 1999–2003 Ford F-250 Super Duty 7.3L Powerstroke
• 1999–2003 Ford F-350 Super Duty 7.3L Powerstroke
• 1999–2003 Ford F-450 / F-550 Super Duty 7.3L Powerstroke
• 2000–2003 Ford Excursion 7.3L Powerstroke
• 1994–2003 Ford E-Series Vans 7.3L Powerstroke
• Navistar T444E diesel engines
• OEM-spec Mahle Original standard thickness cylinder head gasket
• High-strength graphite construction with steel combustion fire rings
• Direct individual replacement gasket (two required for a complete engine)
• Cross-references Victor Reinz 61-10366-00
• Single cylinder head gasket only

Ensure both the cylinder head and engine block decks are verified flat, thoroughly deburred, and cleaned completely free of oil, carbon, and solvent residue before positioning the gasket. Always verify proper gasket orientation over the block alignment dowels; installing a head gasket backward will block critical high-pressure oil feed or coolant transfer ports, causing rapid engine failure. Torque new head bolts or heavy-duty head studs in the factory spiral pattern across multiple progressive stages strictly following the fastener manufacturer’s recommended torque values and lubrication procedures.