The Motorcraft FD-4616 Fuel Filter Kit is the genuine Ford factory original equipment (OEM) replacement dual-stage filtration system engineered specifically for 2003–2007 Ford Super Duty trucks and Excursions equipped with the 6.0L Powerstroke diesel engine. Built to strict Ford engineering standards, this complete kit includes both the chassis-mounted primary fuel/water separator filter and the engine-mounted secondary final fuel filter, ensuring uncompromised fuel delivery, complete water separation, and total protection for sensitive HEUI fuel injectors.

Quick Specs & Kit Inclusions

• Filtration Configuration: Complete two-stage system (chassis HFCM primary water separator + engine valley secondary final filter)
• Primary Element Rating: 10-micron nominal rating featuring patented water-coalescing media and alignment retention tabs
• Secondary Element Rating: 2-micron absolute rating engineered to stop abrasive fine particulate before reaching the fuel rails
• Manufacturing Standard: Genuine Ford Motorcraft Original Equipment Manufacturer (OEM) component
• Emissions Status: 50-state legal (direct OE replacement part)
• Direct Interchange Part Numbers: Ford 3C3Z-9N184-CB, Ford 3C3Z-9N184-CA, Motorcraft FD-4604, Navistar 1843057C92
• What's in the Box: (1) 10-Micron Primary Fuel/Water Separator Element with O-ring, and (1) 2-Micron Secondary Engine Valley Fuel Filter Element with O-ring

Problem Solved: Curing Injector Stiction, Abrasive Wear & Fuel Bypass

Aftermarket "will-fit" fuel filters often omit the patented internal keyways and locator tabs engineered into the factory Ford Horizontal Fuel Conditioning Module (HFCM). Inferior aftermarket primary filters can cock sideways inside the housing or collapse under suction, bypassing emulsified water and raw grit directly into the high-pressure fuel system. Generic secondary filters frequently use cheap 10-to-20 micron paper media instead of true 2-micron depth media. Because 6.0L Powerstroke HEUI fuel injectors operate with micro-inch internal tolerances under intense hydraulic pressure, microscopic particulate and water cause internal plunger scoring, spool valve stiction, erratic idle, misfires, and premature injector failure. Installing the genuine Motorcraft FD-4616 ensures factory-calibrated fuel flow, verified water stripping, and maximum injector service life.

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
• Fitment Note: Designed for F-Series Super Duty pickups, cab-and-chassis models, and Excursions; does not fit Econoline E-Series vans (which utilize Motorcraft FD-4606).

Safety & Primary Water Draining: Park the truck on a level surface, set the parking brake, and shut off the ignition. Place a drain pan directly beneath the HFCM located on the inside driver-side frame rail. Open the brass or 6mm Allen drain plug to evacuate water and residual diesel from the housing. Primary Filter Removal: Using a 36mm (or 1-7/16") socket on a ratchet, unscrew the HFCM filter cap counter-clockwise. Pull the cap and primary filter assembly downward out of the module. Unsnap the old 10-micron element from the cap and remove the old cap O-ring. Primary Filter Installation: Clean the cap threads and the inside of the HFCM reservoir with a clean shop towel. Coat the new primary cap O-ring with clean diesel fuel or motor oil and seat it into the cap groove. Snap the new Motorcraft 10-micron filter element securely into the cap, ensuring the retention tabs align squarely. Thread the cap assembly into the HFCM housing and torque to 19 ft-lbs (25 Nm). Secondary Filter Removal: Move to the engine bay. Using a 24mm (or 15/16") socket, slowly loosen the secondary fuel filter cap located on top of the engine valley fuel bowl. Lift the cap and old 2-micron filter element out of the bowl. Remove the used element and cap O-ring. Secondary Bowl Inspection: Inspect the secondary bowl reservoir. Use a fluid syringe or vacuum extractor to remove any settled dirt, debris, or standing fuel from the bottom of the housing. Clean the threads thoroughly. Secondary Filter Installation: Lightly lubricate the new secondary cap O-ring with clean diesel fuel and install it onto the cap. Snap the new Motorcraft 2-micron filter element into the underside of the cap. Carefully hand-thread the cap onto the secondary housing to avoid cross-threading. Torque the secondary cap to 19 ft-lbs (25 Nm). Fuel System Priming Sequence: Turn the ignition key to the "RUN" position for 30 seconds without cranking the engine to allow the electric fuel pump to fill the HFCM, purge air through the secondary regulator, and pressurize the fuel supply rails. Turn the key off for 5 seconds. Repeat this key cycle 4 to 5 times. Final Leak Check: Start the engine and inspect both the frame-mounted HFCM cap and the engine-mounted secondary fuel bowl cap to confirm a complete, leak-free seal.