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Common 6.7 Powerstroke Problems and How Much You Have to Spend to Fix Those

Some of the most prevalent 6.7 Powerstroke problems are radiator issues, different types of sensor failures, glow plug dropping, turbocharger failure, EGR cooler clogging, and a few more.

Fortunately, the fixing process for all of these issues is quite straightforward. In some cases, you can prevent a specific issue from ever taking place by taking effective measures beforehand.

There are also maintenance practices and performance upgrades that can greatly enhance your 6.7 Powerstroke’s reliability.

In this article, we’ll talk about all common 6.7 Powerstroke issues and how you can prevent or fix them. We’ll also talk about how to increase your vehicle’s durability and reliability. Let’s jump right in.

Key Takeaways:

  • The first generation of Ford 6.7 Powerstroke was released in 2011, and it was full of issues. Ford gradually worked on these issues and improved the overall engine in the subsequent generations.
  • The 2nd and 3rd generations were released in 2015 and 2020, respectively, and the 3rd gen engine is the most reliable among them.
  • 6.7 Powerstroke issues include EGT and NOx sensor failures, turbo failure, coolant leakage, fuel pump issue, and glow plug dropping.

Issues and Improvements History of 6.7 Powerstroke Engine

Although the 6.7L Powerstroke is the 4th generation of Ford truck diesel engines, it’s actually the first engine that Ford produced themselves. Previous Powerstroke engines were manufactured by a company named Navistar International.

The 6.7L V8 Powerstroke had to go through several iterations within the series to reach its current state. After its launch in 2011, it was declared to be the least reliable engine among all generations of Powerstroke.

 Let’s discuss all three engine generations of 6.7L Powerstroke in brief.

1st Generation (2011 to 2014)

This first generation 6.7 Powerstroke engine showed many issues like sensor malfunctioning, turbo failure, cooler clogging, radiator malfunctioning, etc.

2nd Generation (2015 to 2019)

In 2015, Ford released the 2nd iteration of the 6.7L Powerstroke engine, and it showed significant promise. Several reliability issues were fixed by updates like lower bearing coating, stronger crankshaft damper, turbo, and EGR cooler modifications, etc. The engine also got a boost in torque and horsepower.

3rd Generation (2020 to Present)

It’s the 3rd generation of the 6.7 Powerstroke that is currently running in the market with a very impressive power (475 – 500 HP) and torque (1050 – 1200 lb-ft) level. It came out in 2020 and is said to be the most reliable engine version of the series.

6.7 Powerstroke Engine Common Problems: Causes, Signs, and Solutions

In this section, we’ll discuss all sorts of problems that are very common in different Ford 6.7 Powerstroke engine generations. Note that some of these issues are only prevalent in the first gen models.

We’ll also discuss how to identify these issues beforehand, alongside what steps you can take to fix them. Let’s dive in.

1. Turbocharger Malfunction Issues

This problem is most common in the 2011-12 series Ford trucks that come with the 1st gen 6.7L Powerstroke. The two main reasons for frequent turbo failures were –

  • The turbo build is inadequately small, considering the power requested from the engine.
  • Installed ball bearings are made of ceramic, which decay quicker in demanding conditions.

In the 2nd generation engine, the turbo size was extended and made more robust. The ceramic ball bearings were replaced by IROX-coated durable steel bearings. These updates significantly reduced the early turbo failure issues in 6.7L Powerstroke engines.

But eventually, the turbo is supposed to fail in the later generations of 6.7L due to continuous wear and tear of different parts. It can also fail early due to the lack of proper maintenance and driving habits.

Signs:

  • Loud and continuous screeching noise.
  • Oil leakage in the exhaust system.
  • Oil loss due to excess burning.
  • An excessive amount of emission.
  • Decreased engine performance and efficiency.

Solution:

If your 1st generation 6.7L Powerstroke turbo shows signs of malfunction and failure, the only solution is to replace it with a more advanced option.

Unfortunately, the replacement cost will get very high, the turbocharger alone is around $1600 to $1800. The labor cost can get up to $400.

Even if they show signs of failure, contact your trusted mechanic first before deciding on replacing the entire unit. In many cases, replacing some parts or an extensive repair job should be good enough. 

2. EGT Sensor Issues

The 6.7 Powerstroke has 4 EGT sensors, and in almost every first-generation engine, at least 1 or 2 sensors are bound to fail prematurely. Sensors in the later generations are also quite prone to failing early, and that’s why Ford only provides extended warranty service for the sensors.  

EGT (Exhaust Gas Temperature) sensors are sensors that are mostly located around the exhaust manifold and near the turbocharger. They are designed to monitor the temperature of the exhaust gases as they exit the engine.

Signs:

  • Sudden engine shut down.
  • Turned on check engine light.
  • Degraded emission quality.
  • Appearance of DTC fault codes (P2033, P2084, P242A, P2032)
  • Failed result in emission test.

Solution:

Fortunately, EGT sensors are affordable and easy to replace. You can do it on your own if you have enough knowledge about your truck. Many people even keep additional sensors with them in case of emergency.

One EGT sensor will cost around $30 to $50. The labor cost can get a bit high, though, around $150. That’s why, before replacing a faulty sensor, check if the warranty service is still enabled. This may spare you from spending some hard-earned cash of yours.

3. NOx Sensor Failure

A NOx sensor or nitrogen oxide sensor is installed to detect the level of NOx gases in the combustion and exhaust manifolds. This sensor is a very important part of diesel engines with SCR systems that are Urea based.

NOx sensor issues are most common in first-generation 6.7 Powerstrokes, especially with the 2011 models. Back in 2011, this issue became so frequent that Ford launched a Custom Satisfaction Program 12B33.

The program lasted till April 2013, and during this period, corresponding truck owners could get their sensors checked for fault by expert technicians and get a sensor replaced if it was faulty. 

They would also get an SCR (Selective Catalytic Reduction) system upgrade for better emission control and reducing the amount of NOx content in the exhaust. 

Signs:

  • ECM unit commanding the vehicle to go to ‘Limp Mode.’
  • Engine power dropping down severely.
  • Poor exhaust quality.

Solution:

Fixing a faulty NOx sensor means simple parts replacement. The price of a NOx sensor can vary depending on its quality and also where in the vehicle it is located.

Typically, a NOx sensor replacement will cost around $350 to $450. Parts cost can vary from $280 to $400, and the labor cost will be around $50 to $70.

4. EGR Cooler Clogging Issues

Problems with EGR coolers are more common in 6.7L Powerstroke, compared to the previous ones, 6.0L, and 6.4L. Mainly, the problem stems from the EGR cooler design of 6.7L.

EGR coolers are an important part of the engine’s emissions control system as they help to reduce the temperature and nitrogen oxide (NOx) contents from emissions.

The 6.7L cooler design lets carbon and soot build up quickly over time and completely jam the EGR cooler.

Signs:

  • Engine overheating.
  • High-temperature exhaust.
  • Turned on check engine light
  • Appearance of ‘P040’ fault code.

Solution:

EGR cooler issues can be handled in two ways. Let’s take a look

  • EGR Cooler Replacement

If you know your vehicle well and love to do things on your own, replacing the EGR cooler by yourself won’t be any hassle at all.

The entire EGR cooler kit can cost from $200 to over $1000. And the labor cost can be around $60-70.

  • EGR Delete Kit

Another solution is to remove the EGR cooler component altogether and install an EGR delete kit. Although installing an EGR delete kit can boost the engine performance and remove many EGR component-related issues, it’s harmful for the environment as your emission quality will be poorer.

Installing an EGR delete kit is only suitable if it’s legal in your region or your truck is only used in off-road activities.

The price of an EGR delete kit varies depending on its quality and brand. It can range from $200 to even $1500. The labor cost will be around $200-$300.

5. Injection Pump Issues

Prior to the 3rd generation 6.7 Powerstroke models, injection pump failure issues were very common. The 6.7 Powerstroke comes with a Bosch CP4.2 high-pressure fuel pump.

This pump suffers from breaking down owing to the continuous metal-on-metal contact, which allows air inside the pump. The contamination can warrant long-term damage to regulators, fuel injectors, and lines and make the system completely inoperable.

Signs:

  • Stalling due to scarcity of fuel flow.
  • Engine cranking and starting issues.
  • Excessive power loss.
  • Rough engine stuttering.
  • Inoperable engine (complete failure of fuel system).

Solution:

You should be really cautious about the fuel injection pump failure issues of 6.7 Powerstroke. Not detecting the issue timely can cost your entire fuel system which can go up to $10,000.

That’s why it’s important to keep your 6.7 Powerstroke’s fuel system under regular inspection, especially if the vehicle is from before 2020. Replacing the pump will take around $1500 to $1600, where the pump will cost around $1000 and labor cost around $500.

6. Glow Plug Breaking

This issue is way less common than the ones discussed previously, and it only occurred in the 1st generation engines. But the consequence of this issue can be really severe.

What happens is that the glow plug tip can break off and collide with the engine. The result of it can be really damaging.

Signs:

  • No early signs

Solution:

According to Ford, the issue occurred due to some faulty glow plugs. As the issue was seen rarely and only in the early models, you probably don’t have anything to worry about.

But if you drive an older version of a Ford truck with 6.7 diesel, you may want to get the glow plug checked just to be sure.

7. Radiator Coolant Leak Issue

The coolant leakage issue from radiators is a pretty common issue for all generations of 6.7 Powerstroke diesel engines. This leakage issue occurs more frequently on the primary radiator and can drop the engine performance.

Signs:

  • Leakage of coolant.
  • Overheating.
  • Decreased engine performance.

Solutions:

Radiators of 6.7 Powerstroke cost around $400-500, and it isn’t much of a hassle to install on your own. If you don’t want to install it on your own, the labor cost can be around $120.

6.7L Powerstroke Diesel V8 Care and Maintenance

Although the 6.7L Powerstroke engine has quite a few reliability concerns, regular care and periodical maintenance can keep some of these issues from occurring. Let’s take a look at the steps below.

● Change the Oil and Oil Filter Regularly

The oil in your 6.7 engine helps to lubricate and protect the internal components. Over time, it can become contaminated and lose its effectiveness.

Be sure to change the oil and oil filter at the recommended intervals to keep your engine running smoothly.

● Fuel System Maintenance

As I stated before, the fuel pump is one of the weakest links of 6.7L Powerstroke engine generations. To avoid unwarranted situations and extremely expensive repairs, you should check your fuel system yourself or with an expert mechanic regularly.

Also, be sure to use diesel fuel that meets the manufacturer’s specifications and is free from contaminants. This will also enhance your fuel system’s longevity by a great deal.

● Regular Inspections

It’s essential to do regular inspections of your 6.7L Powerstroke’s components, especially those which are prone to failure like turbo, EGT sensor, etc.

Also, check the hoses, belts, and similar components which are subjected to continuous wear and replace them whenever needed.

● Replace the Fuel Filters

The 6.7 Powerstroke has two fuel filters, a primary filter, and a secondary filter. Replace these filters at the recommended intervals to prevent contaminants from reaching the fuel injectors.

FAQs

Is 6.7L Powerstroke reliable?

The most recent versions of 6.7L Powerstroke, especially after 2020, are quite durable and reliable for heavy-duty uses.

It’s not like they don’t have their issues, but the updates and modifications have taken care of some major concerns. Before buying your own, make sure to avoid the worst years of 6.7L Powerstroke.

Will bulletproofing help improve 6.7 Powerstroke’s reliability?

Yes, it will. Bulletproofing is the process of replacing the OEM parts and components, especially the ones prone to failure, of an engine with more durable and reliable aftermarket products.

But it can cost a good amount depending on the level of power and performance you are demanding from your vehicle.

Conclusion

It’s true that Ford 6.7 diesel engine problems and reliability issues are no small deal, especially compared to some of the older diesel engine designs. But there are ways to reliably fix these issues. Some cost less, and some cost a bit more.

If you can afford to pay for the solution and bulletproofing required, Ford 6.7 Powerstroke diesel can be an absolute powerhouse. But in the end, it all comes down to your need and preference.

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