The Driven Diesel DD-60FS-STD-RRK-V2 Standard Regulated Return Fuel System Kit is a complete parallel-flow fuel conversion engineered specifically for 2003–2007 Ford Super Duty trucks and Excursions equipped with the 6.0L Powerstroke diesel engine. Designed to retain the factory secondary fuel filter bowl in the engine valley, this Version 2 kit converts the failure-prone factory "dead-headed" fuel rail layout into a continuous, parallel regulated loop. By feeding fuel through both cylinder heads and returning aerated excess fuel through a custom Fuelab bypass regulator, it balances rail pressure from front to rear, eliminates fuel starvation at cylinders #7 and #8, and extends the service life of expensive HEUI injectors.

Quick Specs & Kit Inclusions

• System Architecture: Standard regulated return (retains factory engine-mounted secondary fuel filter bowl)
• Fuel Pressure Regulator: Custom Fuelab billet aluminum adjustable bypass regulator (custom tunable from 45 to 75+ PSI)
• Lines & Tubing: CNC-bent rigid stainless steel hard lines for tight engine clearance areas combined with high-pressure stainless steel braided Teflon hoses with protective black outer sleeves
• High-Flow Banjo Hardware: Includes Driven Diesel high-flow stainless steel front banjo bolts and new copper crush washers
• System Monitoring: Includes a Driven Diesel liquid-filled 0–100 PSI mechanical fuel pressure gauge
• Regulator Mounting: Precision T-304 stainless steel mounting bracket engineered for alternator mounting
• 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-STD-RRK-V2, DD-60FS-STD-RRK
• What's in the Box: (1) Custom Fuelab Adjustable Bypass Regulator, (1) Driven Diesel Liquid-Filled Fuel Pressure Gauge, (1) T-304 SS Regulator Bracket, (1) Complete Set of CNC-Bent SS Hard Lines & Braided Teflon Hoses, (2) High-Flow SS Banjo Bolts with Copper Washers, AN Fittings, and Detailed Installation Hardware

Problem Solved: Eliminating Dead-Head Rail Starvation & Injector Cavitation

From the factory, the 6.0L Powerstroke utilizes a dead-headed fuel rail configuration where fuel enters the front of each cylinder head with no exit path other than through the injector nozzles. Fuel trapped at the rear of the heads absorbs intense combustion heat and accumulates aerated bubbles. During heavy throttle, towing, or performance tuning, dynamic pressure drops severely at rear cylinders #7 and #8. When fuel pressure dips below 45 PSI, fuel cavitates, removing the liquid hydraulic cushion required to absorb the reciprocating stroke of the HEUI intensifier piston. This causes internal piston scoring, cracked nozzles, injector stiction, rough running, and premature failure. The Driven Diesel DD-60FS-STD-RRK-V2 establishes a continuous parallel loop that purges aerated fuel back to the tank, equalizes pressure across all eight cylinders, and allows precise pressure adjustment to keep injectors properly cushioned.

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 & Application Notes:
  • Retains Factory Fuel Bowl: Engineered specifically for trucks retaining the factory engine-valley secondary fuel filter bowl. (If you want to delete the bowl, use kit # DD-60FS-FBD-RRK-V3).
  • Lift Pump Compatibility: Compatible with the stock frame-mounted HFCM lift pump as well as aftermarket systems (such as FASS or AirDog).
  • Intake Manifold Clearance: Clears factory intake manifolds as well as aftermarket performance manifolds (such as Odawg S2/S3).
  • 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. Slowly loosen the secondary fuel filter cap (24mm socket) in the engine valley to relieve residual system pressure and allow fuel to drain down. Access Preparation: Remove the upper intercooler (CAC) piping, air intake ducting, and loosen upper engine harness looms to access the front and rear cylinder head fuel ports. Place absorbent shop towels beneath all fuel ports. Front Supply Line Upgrade: Remove the factory front fuel lines and restrictive OE banjo bolts. Install the Driven Diesel high-flow stainless steel banjo bolts and lines using the supplied copper crush washers (one washer on each side of the banjo fitting), torqueing each bolt to 20 ft-lbs (27 Nm). Rear Return Port Connections: Locate the square-drive pipe plugs at the rear of both cylinder heads. Remove the plugs, clean the port threads, and thread the supplied AN adapter fittings into the rear fuel rail ports. Regulator Mounting & Hose Routing: Mount the T-304 stainless steel bracket and Fuelab bypass regulator to the alternator mounting location. Connect the pre-formed stainless steel return hard lines and flexible black-sleeved braided Teflon hoses from the rear head ports to the regulator inlet ports. Route the regulator return line back into the fuel return circuit. Gauge Installation: Thread the Driven Diesel 0–100 PSI liquid-filled gauge into the dedicated 1/8" NPT port on the Fuelab regulator body using PTFE thread sealant paste. Fitting Torque: Tighten all AN swivel line ends using an aluminum AN wrench until fully seated to 15–18 ft-lbs (20–24 Nm); do not over-torque. Verify the secondary fuel filter cap is torqued to 19 ft-lbs (25 Nm). Priming, Pressure Adjustment & Leak Verification: Reconnect the battery terminals. Cycle the ignition key to "RUN" (KOEO) for 30 seconds without cranking to let the lift pump purge air through the regulator. Loosen the locknut on top of the Fuelab regulator and adjust the set screw until running fuel pressure stabilizes at 60–65 PSI, then lock down the nut. Closely inspect all front banjos, rear head ports, regulator fittings, and lines for zero fuel seepage before starting the truck.