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BLACK FRIDAY → Driven Diesel 6.0L Standard Regulated Return Fuel System Kit

Driven Diesel 6.0L Standard Regulated Return Fuel System Kit

6.0L FUEL SYSTEM FLOW DIAGRAMS (opens in new window)
This item requires Vehicle Fitment, please select Vehicle first!
OR if you know the Part Number you need, select from Options below.

DD-60FS-STD-RRK-V2

Part Number: DD-60FS-STD-RRK-V2
Availability: In Stock
Instructions: (Adobe Reader required)
Regular Price: $749.95
On Sale Now: $674.96
CARB EO #: D-872-2 (03-07 F250/F350/Excursion ONLY!)
CARB Approved - CARB EO# : D-872-2 (03-07 F250/F350/Excursion ONLY!)

The Driven Diesel Regulated Return Kit for the 03-07 6.0L Powerstroke Super Duty is an important part of the fuel system upgrade process. This kit eliminates the "dead-head" stock fuel rails and provides adjustable fuel pressure capability to the Powerstroke fuel system. This is done by tying the end of each fuel rail together through a Bypass Fuel Pressure Regulator. The Driven Diesel Regulated Return Kit also includes replacement Fuel Feed Lines (from the fuel filter to the cylinder heads) that replace the stock lines and banjo bolts with larger high flow units and eliminate the restrictive check valves.

The primary benefit of this kit is SIGNIFICANTLY increased fuel flow "through" the heads, ensuring that each fuel injector has adequate fuel volume and pressure all the time (no more "Wide Open Throttle Pressure Drop"). If you want increased injector life and less injector noise...particularly if you are installing expensive new injectors (stock or aftermarket), we HIGHLY RECOMMEND this kit to protect your investment!

Below are some of the key features of the Driven Diesel Regulated Return Kits:
• CARB Approved - CARB EO# : D-872-2 (03-07 F250/F350/Excursion ONLY!)
• Will Clear Stock and Aftermarket Turbocharger Setups
• No Interference With Intercooler Tubes!
• Will fit BOTH Single and Dual Alternator Engines
• EXCLUSIVE Custom Return Fitting with Integrated Fuel Filter Air Bleed Made in the USA!
   (Driven Diesel is the ORIGINATOR of the Custom Machined Filter Bowl Fitting!)
• Driven Diesel Custom High Flow Banjo Bolts Made in the USA!
• NEW Ford Fuel Bowl Fitting O-Ring Included!
• High Quality FueLab Bypass Fuel Pressure Regulator Made in the USA!
• 12ga T-304 Stainless Steel Regulator Mounting Bracket Made in the USA!
• Marshall Liquid Filled Fuel Pressure Gauge
• Custom CNC Bent S.S. Hard Lines with High Flow Banjo Fittings Made in the USA!
   (These are NOT modified stock lines like some of our competitors use!)
• High Quality S.S. Braided Teflon Fuel Lines with BLACK Protective Covering Made in the USA!
• Complete Kit with All Necessary Parts and Detailed Instructions
• Special Long Handled 6mm Allen Tool Included!

Made in the USA! Denotes Items that are 100% MADE IN THE USA!

FITMENT NOTE : Driven Diesel 6.0L Regulated Return Kits locate the regulator using a bracket mounted to the alternator. Some Aftermarket/High Amp alternators use a different housing that is not compatible with the Driven Diesel regulator bracket. Modifications to the Driven Diesel regulator bracket, or fabrication of a different mounting bracket, may be required in vehicles with oversized, aftermarket alternators.

Note: Use of this kit ELIMINATES the stock fuel pressure regulator assembly completely. You DO NOT need the Ford "Blue Spring" kit when using our Regulated Return Kit!!!

WITH THE EXCEPTION OF ITEMS LISTED IN THE FUEL SYSTEM COMPONENTS SECTION OF OUR WEBSITE, WE DO NOT SELL INDIVIDUAL PIECES OF OUR FUEL SYSTEM KITS.

We make every attempt possible to source and use as much U.S. made product/material as we possibly can...as long as doing so doesn't sacrifice the quality of the final product. We can't always control where every component of one of our products comes from, but you count on us to keep looking for ways to increase the % of American Made parts and materials in the products that we produce.

. . : : BUYER BEWARE : : . .

JUST BECAUSE A COMPETITORS FUEL SYSTEM KIT LOOKS "SIMILAR" TO OURS...DOESN'T MEAN IT WORKS LIKE OURS. WE'VE BEEN BUILDING POWERSTROKE DIESEL FUEL SYSTEMS SINCE 2001, AND 6.0L SYSTEMS SINCE 2003. WE'VE DONE THE RESEARCH AND ACTUALLY UNDERSTAND THE PRODUCTS WE ARE DESIGNING AND SELLING, WE DID NOT JUST BUY SOMEONE ELSES PRODUCT AND TRY TO COPY IT FOR PROFIT. IF YOU WANT THE BEST THERE IS FOR YOUR POWERSTROKE DIESEL, DON'T SETTLE FOR LESS THAN A DRIVEN DIESEL ORIGINAL FUEL SYSTEM KIT!

Customer Reviews

(4.33)stars out of 5
# of Ratings: 12
(Only registered customers can rate)
1. on 7/30/2020, said:
5 stars out of 5
Great kit, very happy with the quality of the components and well worth the cost.
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2. on 10/22/2018, said:
5 stars out of 5
The good: It's on and it makes a huge difference! when cranking the truck cold the injectors would have the loud clatter then settle in. Now when cranking the injectors are so quiet I can here myself thinking. Fuel pressure is constant under throttle or idling. Seems to have better seat of the pants response now but I also installed an Odawg S3R intake to go along with it. I am having 205/75 injectors go in next. Now the bad or not so bad: everything was going fine until I had to remove the rear head banjo bolts. After cussing out the truck and damn near taking my plasma cutter to cut the entire truck in half I decided to take a break for a few minutes. The trick is to drink 2 orange Gatorades and ask Jesus for forgiveness for all that cussing. It was hard to get the allen wrench in the plug holes but I got it. Now for the relevant stuff: All hoses and tubes worked and fit like they were supposed to, the only problem I had was on the S3R intake the sensor on the driver side of the intake was touching the Driven Diesel front fuel bowl cover and I had to muscle the connector down into the sensor. Not either sides fault I suppose but it was an issue for me. You have to have the sensor threaded in the exact right position to get the connector down. I am happy I did this myself and saved money but I will not do it again lol. Also make sure you check for leaks like the paperwork says because a had a small one on the fuel bowl but a quick snug of the inside nut did the trick. Thank you Strictly Diesel for the high quality parts, I feel like I deserve a T-shirt for my accomplishment,...just kidding.
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(12 people found this comment helpful, 1 did not)
3. on 3/21/2018, said:
4 stars out of 5
Great kit. My issue was with the drivers side line on the back of the block. The angle was wrong and could not get the banjo bolt to start. This pretty much added another full day to the install. It took two trips to the vice to put some small bends in the line and removal of the top half of the engine. We removed both fender wells and totally loosened the up pipes. Had the angle been right we probably could have left it all in tact. We also drained the radiator and removed the hose that was blocking the banjo bolt on the front of the head on the drivers side.
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(7 people found this comment helpful, 1 did not)
4. on 12/5/2017, said:
5 stars out of 5
This is a real high quality kit with probably the best installation directions out there. The only thing I would add is an flow chart at the end showing the flow path of fuel for troubleshooting purposes.
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(7 people found this comment helpful, 1 did not)
5. on 8/29/2017, said:
5 stars out of 5
Great product and works just as advertised. I used this and the fuel bowl delete later along with the adapter kit to the Air dog2. Everything has great instructions and is easy to follow. They make it as simple as they can for install. The only regulated return kits I'll ever use on any of my vehicles. Great customer service. Thanks for the swag pack
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(6 people found this comment helpful, 0 did not)
6. on 9/24/2014, said:
5 stars out of 5
I've done my research on home brew regulated return kits as well as other regulated return kits on the market. After seeing the competitor kits I thought; "I can do this, just run down to the local hydraulic fitting store and build my own." Well, long story short its not so easy and when I sucked it up and bought the Driven Diesel kit I will say it is worth every penny. This kit cannot be replicated with store bought items, you realize this when it shows up at your door. Nothing is "off the shelf," So learn from me and just do it right the first time with this kit!
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7. on 2/19/2014, said:
5 stars out of 5
After seriously considering the goals I have for my truck (longevity and reliability being at the top), I decided to purchase this kit. My Ford dealer said they had not installed a regulated return kit before, but they have seen a few already on trucks. They took a look at the instructions and said they could do it in 4-6 hours at a (discounted) rate of $75 per hour. I then determined to do it myself. This is rated as a "difficult" install - with which I would definitely agree unless the engine was pulled ;-) Because I had 2 new banjo bolts and 4 copper washers to begin with and a full set of 4 bolts and 8 washers came in this kit, I had some extras. The extra washers came in handy, as they are often difficult to place and I admit I lost one or two of them. Though the regulated return install took me more than 6 hours (would be easier without a second alternator or with the engine pulled), I am glad I did it myself. After seeing everything myself and putting my own hands on it, there is no denying that this is the way the truck should have come from the factory. There are even brackets on the rear of the engine that help route the rear fuel lines, though the fuel lines didn't come stock on this engine (makes you wonder, doesn't it). This is truly one of those upgrades that makes me smile on the inside. It's not anything flashy. It won't draw any attention as you drive down the road, but I believe it will allow you to drive down the road further, more reliably and with lower repair costs than the guy next to you.
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Frequently Asked Questions
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Driven Diesel 6.0L Standard Regulated Return Fuel System Kit fits the following vehicle(s):

  • 2003 Ford Excursion 6.0L
  • 2004 Ford Excursion 6.0L
  • 2005 Ford Excursion 6.0L
  • 2003 Ford F250/350 Super Duty 6.0L
  • 2004 Ford F250/350 Super Duty 6.0L
  • 2005 Ford F250/350 Super Duty 6.0L
  • 2006 Ford F250/350 Super Duty 6.0L
  • 2007 Ford F250/350 Super Duty 6.0L
  • 2003 Ford F450 Super Duty 6.0L
  • 2004 Ford F450 Super Duty 6.0L
  • 2005 Ford F450 Super Duty 6.0L
  • 2006 Ford F450 Super Duty 6.0L
  • 2007 Ford F450 Super Duty 6.0L
  • 2003 Ford F550 Super Duty 6.0L
  • 2004 Ford F550 Super Duty 6.0L
  • 2005 Ford F550 Super Duty 6.0L
  • 2006 Ford F550 Super Duty 6.0L
  • 2007 Ford F550 Super Duty 6.0L
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