Setting up a 6.0 ccv reroute is often the first "mod" many owners tackle once they realize their intercooler boots are starting to look like they've been dipped in a vat of oil. If you own a 6.0L Powerstroke, you already know that these engines have their quirks, but the way the factory handled crankcase ventilation is one of those things that just seems to cause more headaches than it's worth over time. It's a simple system, really, but the side effects of leaving it stock can lead to a messy engine bay and some annoying maintenance issues down the road.
Why the Stock Setup is a Mess
The factory Crankcase Ventilation (CCV) system on the 6.0 is a "closed" system. This means the engine takes all that oily, hot vapor that builds up in the crankcase and dumps it right back into the intake tract, usually right before the turbocharger. The idea from an emissions standpoint makes sense—you're burning off those vapors instead of venting them into the atmosphere. But in practice, it's a bit of a disaster for the health of your intake system.
When that hot oil mist hits the cold air coming into the turbo, it starts to condense. This creates a fine film of oil that coats everything it touches. It gets on the turbo compressor wheel, it lines the inside of your intercooler pipes, and eventually, it pools up in the bottom of your intercooler. It's not just a "cleanliness" issue, either. That oil is a nightmare for the rubber and silicone boots that hold your charged air system together.
Saving Your Intercooler Boots
If you've noticed your truck is losing boost or you see oil weeping from the connections on your intercooler pipes, you're seeing the CCV system's handiwork. Oil and rubber don't play well together. Over time, the oil mist saturates the silicone boots, causing them to soften, swell, and eventually slip off under pressure. There's nothing quite like the sound of a boot blowing off when you're merging onto the highway with a trailer behind you—it sounds like a shotgun going off and suddenly you've got zero power.
By performing a 6.0 ccv reroute, you're essentially cutting off that oil supply. Once you stop the mist from entering the intake, your boots stay dry and "tacky," which helps them grip the pipes much better. It's a massive upgrade for reliability, especially if you've stepped up to higher boost levels with a tuner.
How a CCV Reroute Actually Works
The process is actually pretty straightforward. You're taking the vent that sits on the driver's side valve cover and redirecting it. In the stock configuration, there's a plastic elbow and a tube that runs over to the large air intake duct.
To do the reroute, you remove that connection to the intake and plug the hole left behind. Then, you attach a new, longer hose to the valve cover vent. Where you run that hose is where things get a bit more interesting, and there are generally two ways people go about it.
The Atmosphere Vent
The simplest and most common method is the "vent to atmosphere" setup. You basically take a long piece of 1-inch or 3/4-inch hose (depending on your specific kit or DIY setup) and run it down the side of the engine, along the frame rail, and let it exit somewhere near the back of the cab.
The pros? It's cheap, there are no moving parts, and it's impossible to clog. The cons? You might notice a little bit of "smoke" or vapor coming from under the truck when you're stopped at a light. Also, you'll eventually get a small oil drip on your driveway where the hose ends. Most guys don't mind a little "truck sweat," but it's something to keep in mind.
The Catch Can Method
If you want to keep things a bit cleaner, you can install a catch can or an oil separator. In this setup, the hose from the valve cover goes into a canister that's mounted somewhere in the engine bay or on the frame. The canister has baffles or a filter that traps the oil droplets while letting the air escape.
This is definitely the "polite" way to do a 6.0 ccv reroute. You don't get the smells, and you don't get the drips on the pavement. The only catch is that you have to remember to drain the canister every few thousand miles. You'd be surprised how much oily gunk those things can collect in a short amount of time.
Better Performance for Your Turbo
We often talk about the intercooler boots, but the turbocharger itself really appreciates a cleaner diet. When oil mist constantly hits the compressor wheel, it can lead to carbon buildup. While a little oil isn't going to kill a turbo instantly, keeping that wheel clean ensures you're getting the best possible airflow and efficiency.
Also, when that oil mixes with any fine dust that might make it past your air filter, it creates a sort of abrasive paste. It's not exactly "sandpaper," but it's definitely not what you want spinning at 100,000 RPM. A 6.0 ccv reroute ensures that the only thing your turbo is sucking in is fresh, filtered air.
Dealing with the Smell
One thing nobody tells you until after you've done the mod is that diesel crankcase vapors have a very distinct aroma. It's a mix of hot oil and blow-by gases. If you just dump the hose right under the driver's seat, you're going to smell it every time you roll down the window at a stoplight.
The trick is to run the hose far enough back—usually past the back of the cab—so the draft of the truck moving pulls the scent away. Some people even tie the vent into the exhaust pipe using a venturi bung, which actually uses the exhaust flow to pull a slight vacuum on the crankcase, but that's getting into some more advanced fabrication territory.
Is it Worth Doing Yourself?
You can find a lot of pre-made kits for a 6.0 ccv reroute online, and honestly, they're pretty affordable. They usually come with a nice CNC-machined plug for the intake and the correct fittings for the valve cover. It makes the job look professional and "factory," which is nice if you care about how the engine bay looks when you open the hood.
However, if you're a DIYer on a budget, you can definitely head to the hardware store and piece it together for about twenty bucks. A few feet of heater hose (make sure it's oil-resistant), a couple of clamps, and a hardware store plug for the intake will get the job done. It won't be as "pretty," but the engine won't know the difference.
Final Thoughts on the Reroute
At the end of the day, the 6.0 ccv reroute is one of those modifications that falls into the "preventative maintenance" category. It's not going to give you an extra 50 horsepower or make the truck sound like a race car, but it is going to save you from sticky messes, ruined boots, and a gunked-up intercooler.
If you plan on keeping your 6.0 Powerstroke for a long time, it's almost a no-brainer. It solves a genuine design flaw without costing an arm and a leg. Just be prepared for that one friend to tell you your truck is "smoking" from underneath when they see the vent tube doing its thing—you'll just have to explain that it's finally breathing the way it should have from the factory.