6 Symptoms of 6.0 Powerstroke Weak Fuel Pump (You Shouldn’t Overlook)

A bad or weak fuel pump is very easy to indicate as you will notice some common signs with your vehicle which was not present earlier. For example, you will start hearing strange noises, often engine misfires or the engine stops responding.

I will be getting into detail about the common symptoms of a 6.0 Powerstroke weak fuel pump very soon. Before that, in this article, I will be talking about what are the causes, costs, and other relevant topics you should be aware of when your vehicle is facing such issues.

At a Glance:

SymptomsPossible Causes
Loud Strange NoisesDue to the weak fuel pump, less fuel is supplied to the engine resulting in loud noise.
Engine Warning Light OnEngine detects a problem with the fuel pump; thus, it shows the warning light.
Engine Does Not Turn OnThe fuel pump pressure is low. So, the engine does not get enough power to turn on.
Acceleration IssuesWhen the fuel pump doesn’t deliver the required level of fuel, the engine responds inconsistently to the throttle.
MisfiresA bad fuel pump can lead to a lean air/fuel mixture, which can cause the engine to misfire.
Extreme vibrationThe inability of the fuel pump to provide the needed amount of fuel causes the engine to jerk.

6 Common 6.0 Powerstroke Weak Fuel Pump Symptoms

A weak fuel pump can be identified by the key symptoms described here. However, a weak fuel pump might not also be the case of worry.

Here are detailed descriptions of how you can confirm that the fuel pump is already compromised –

1. Loud Strange Noises

If you start hearing unusually loud sounds from the engine then there are chances of a weak fuel pump.

Now, engine usually makes a typical type of sound. And if you’re familiar with it, you can distinguish whether the noise is specifically for the weak fuel pump, or something else.

When the issue is with the fuel pump, you will hear a whining noise from the engine. That’s how you can confirm the problem type.

2. Engine Warning Light On

In the dashboard, you will notice that the engine warning light is illuminated, and usually it’s not. As the fuel pump does not work, your car will experience low fuel pressure. This will lead your engine to be unable to start.

3. The Engine Does Not Turn On

As your engine is not receiving enough fuel due to low fuel pump pressure, it will not start. If the fuel pump is unable to produce adequate pressure, it will cause engine stalls.

If the fuel pump is not the issue, then get the other compartments checked to identify the actual cause.

4. Acceleration Issues

Another common symptom of a weak fuel pump is, the engine might not respond to the acceleration. This happens because the fuel pump isn’t delivering the required level of fuel to the engine. As a result, the engine isn’t getting the energy needed to respond to the acceleration.

5. Misfire

When the fuel pump malfunctions, then gas cannot be pushed into the engine at the required pressure. This will lead to the engine misfiring exactly when you are trying to turn it on. If the engine continues to behave like this, then it will damage the engine parts significantly.

6. Extreme Vibration

The 6.0 Powerstroke engine might start to vibrate if the fuel pressure is not enough. If you notice any vibrating noises from the engine or feel like the car is shaking much more than usual then get the fuel pump checked. Vibrations caused due to a weak fuel pump are going to come from the cylinders and engine.

Read This Article: Malfunctioning ICP Sensor in 6.0 Powerstroke Engines

7 Reasons Why a 6.0 Powerstroke Fuel Pump Becomes Weak

The common causes of a weak fuel pump are –

  1. The fuel pressure sensor might be faulty and reports inaccurate pressure.
  2. Any of the fuel injectors of your vehicle might be damaged.
  3. The fuel you are using might be contaminated with moisture or dirt.
  4. If the fuel filters are clogged, then less fuel will be pumped into the engine.
  5. The aluminum lines underneath the vehicle might become compressed which causes rupture on the fuel pressure line, so fuel leakage occurs.
  6. Defect on the fuel pressure regulator causes failure to correctly regulate the pressure.
  7. If none of the above works, then the fuel pump might be defective causing low fuel pressure.

How to Test a 6.0 Powerstroke Fuel Pump?

  1. First, ensure that your vehicle is not turned on as the engine is going to be hot along with the fuel.
  2. Once the engine has cooled down, to be on the safe side, get rid of the fuel filter and drain the excess fuel.
  3. Buy a fuel pressure gauge from any automotive store and attach it to the fuel pump test fitting.
  4. The fuel pump test point is around the fuel injectors.
  5. Let the engine warm up and have someone else rev up the engine while you keep a watch at the gauge.
  6. You need to account the pressure both at the rated speed and idle speed.
  7. Rev the engine and check what the pressure gauge reads.
  8. If there are major issues with the fuel pumping system, then the needle will fixate at a place or go down below specifications.

Another method is by disconnecting the fuel pressure sensor and checking how the car performs. If it is faulty, then it is going to disrupt the fuel flow, leading to poor fuel mileage.

Rev the engine after disconnecting the pressure sensor and check if the fuel flows without any issues.

What You Can Do to Deal with a 6.0 Powerstroke Weak Fuel Pump – Fixing Guide

Replacing the fuel pump isn’t the only option you should opt for without trying anything else. If the issue is a minor one, any of the following tips can help –

  1. Check if the inertia switch is on which stops the flow of gasoline to the pump.
  2. Ensure the fuel that is pumping through your vehicle is new and free of any contaminants.
  3. Change the fuel filters often so that they do not get clogged often. The changing interval is around 15,000 miles or 12 to 14 months, or whichever comes first.
  4. Replace the defective parts for smooth fuel pressure.
  5. Inspect all the fuel pump parts and joints to check that nothing is obstructing the fuel pump pressure.
  6. Install a fuel pressure gauge which is going to indicate when your car is facing trouble to pump fuel.

6.0 Powerstroke Weak Fuel Pump Replacement Cost

For a Ford 6.0 Powerstroke, the cost will be between $220 to $1,062 to replace the car’s fuel pump. Replacing the fuel pressure sensor, the cost will be within $250 to $400.

Since all of the tasks are carried out by a professional, you have to pay a labor cost of a minimum $124 and a maximum $260.

Keep in mind, that the repair costs might be higher depending on the underlying issue of your vehicle. The simpler the issues the lower the cost.

How to Prevent Powerstroke 6.0 Fuel Pump from Becoming Weak?

  1. The most important thing is to check if all the parts are working fine. If you continue running the vehicle with faulty parts then it is going to cause irreversible damages.
  2. Always replace the fuel filters after 15,000 miles. They can get clogged very easily and they are impossible to clean.
  3. If you are getting the fuel pump replaced, get a good quality pump even though it will cost extra.
  4. Use a fuel system cleaner to clean the system every once a while which promotes smooth fuel pump.
  5. Install the right size of fuel tank gasket size to ensure that the part does its job correctly.
  6. Not having enough fuel in the tank is also going to affect the longevity of the fuel pump pressure. While the vehicle is running, ensure that optimum fuel level is maintained.
  7. If you are replacing or removing the fuel tank at home, ensure that no dirt or debris gets into the parts. It will contaminate the fuel faster.
  8. The fuel lines should have adequate pressure for supporting the injectors with the current amount of fuel. You might see low fuel pressure symptoms if there’s an issue.
  9. Lastly, it is a wise decision to take your vehicle to a professional regularly and get it check thoroughly to be aware of any defectives.


Can the fuel pump be replaced?

The fuel pump can be replaced, but it should be done by a professional. Doing it at home will cause various issues and might put you into harm’s way. If the fuel pump is not displaying any signs of distress, then you should not change it.

How to know if the 6.0 Powerstroke fuel pump is bad?

When the fuel pump experiences issues, your vehicle will start to show various unwanted signs. For example, the car will be unable to pick up speed, power loss, engine sputters, fuel tank noises or the engine misfires.

How does a Bad Fuel Pump Sound?

The fuel pump usually makes a humming noise, but that’s not typically heard. If you hear a loud whining noise coming from the engine or gas tank, then it’s the fuel pump going bad.

Will driving with weak fuel pressure cause damages to the car?

Your car will face significant drivability problems and the performance will decline. The engine will start to surge and it is dangerous to drive with a surging engine.

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