Top 5 Common Ford 6.7 PowerStroke Diesel Engine Problems (2023)

Ford's 6.7 PowerStroke engine is the fourth generation of diesel engines powering Ford pickup trucks. However, the 6.7-liter V8 is actually the first PowerStroke to be manufactured directly by Ford. Earlier engines were from Navistar International. Now in its third generation, the 6.7-litre diesel engine offers best-in-class power and torque. It is an excellent engine with its 475 hp and 1050 torque. However, all engines are prone to problems and the Ford 6.7 PowerStroke is no exception. In this article, we discuss some of the most common Ford 6.7 PowerStroke engine problems.

Top 5 Common Ford 6.7 PowerStroke Diesel Engine Problems (1)


We will write a detailed post about the different engines of the 6.7L generation in the near future. However, it is an important topic that should be briefly discussed before delving into general issues. We give a brief breakdown of the 3 genes below.

1. Generation Ford 6.7 Diesel V8

Years: 2011-2014

Again, this was the first of Ford's PowerStroke engine series to be homegrown. The first generation PowerStroke 6.7L is said to be the least reliable of the three. It makes sense as it was the first variant of Ford's PowerStroke engines. Almost every early model engine from any company has some teething problems to deal with. That's not to say the first generation is a terrible engine. However, if you have reliability concerns and are on a budget, consider second or third generation options.

6.7 second generation PowerStroke

Years: 2015-2019

Ford's second-generation 6.7 diesel features some notable improvements over the original engine. Some of the updates include:

  • IROX coating on the lower main bearing
  • heavy crankshaft damper
  • Fan clutch upgrade
  • Turbo upgrades to support additional power and torque
  • EGR cooler flow

This is not an exhaustive list of updates for the second generation engine. However, as you can see there have been some major upgrades to the 6.7-litre PowerStroke, some aimed at improving reliability over the initial 6.7-litre engine. Some of the updates also focus on improving torque and power.

Third generation power stroke 6.7

Years: 2020+

The PowerStroke 2020 update is another good one. Since its launch, the engine has delivered best-in-class power and torque. The engine is still new, however, so it's hard to say how reliable the third-generation 6.7-litre PowerStroke will be over the long term. However, we suspect it should be an improvement over previous engines.

(Video) Everything Wrong with the 6.7L Powerstroke

Let's leave it at that for now as the engine is still too new to tell. Again, we'll cover generations in more detail in another post and link to it here.

6.7 Common PowerStroke Issues

Some common crashes with 6.7 PowerStroke are:

  • EGT sensor failure
  • EGR cooler clogged
  • Injection pump failure
  • Radiator coolant leaks
  • Turbocharger problems

This is not an exhaustive list of everything that can go wrong. It's also important to note that just because something is on this list doesn't mean all 6.7-litre PowerStroke engines will have these issues. However, these are some common faults with Ford's 6.7-liter diesel V8. We'll address each of these issues below, and end the post with general thoughts on the reliability of the 6.7-litre Power Stroke.

1) Failure of the sensor 6.7 PowerStroke EGT

Exhaust gas temperature (EGT) sensor problems are among the most common problems on 6.7 PowerStroke engines. The 6.7 liter V8 uses a total of 4 EGT sensors, so there are some potential areas for error. Ford issued an extended warranty to cover EGT in the event of a failure. Hopefully you have the extended warranty, otherwise you'll be paying out of pocket. Even after the first replacement, the 6.7-liter EGT sensors can fail again. EGT sensors 12 and 13 (the middle two) seem to be the most common faults.

Some also choose to rule out the EGT sensors as they can be too much of a problem. Before 2015, these issues could leave you at a loss. Luckily Ford issued a service bulletin in 2015 to update the PCM and reduce the chance of getting stuck on a simple EGT sensor failure. Nevertheless, it can be a good idea to carry an additional sensor in the truck.

Sintomas des Sensors PowerStroke 6.7 EGT

Symptoms that could indicate an EGT sensor failure include:

  • Check the engine light
  • error codes
  • Emission test failed

Typically, once the PCM detects a problem with the EGT sensor, it activates the check engine light. You will also likely get a DTC pointing in the direction of the sensor in question. P0544, P2031, P2032, P2033, P2084, P242A, P242D, P2471, and P246E are among the most common trouble codes that the 6.7L Power Stroke can generate. Prior to 2015, typically the EGT 13 sensor would cause limp home mode and the inability to drive the truck. Some have also experienced this issue after the PCM update.

6.7 Replacing the Power Stroke V8 EGT sensor

If any of these sensors are defective, check if you have the extended warranty or the original factory warranty. However, some under warranty still choose to carry an extra sensor and do the job themselves. The sensors on the 6.7-litre Ford EGT run the full length of the exhaust and are very easy to access. Most can probably get the job done in 15 minutes, and the sensors are only $35-$50.

Make sure the exhaust isn't too hot to work with. Otherwise, it's as simple as a repair can be. For this reason, many choose to carry an extra sensor or two. Going to the dealership for warranty work may be too much of a hassle for some.

(Video) Ford's 6.7 PowerStroke | Reliability and Common Problems

2) 6.7 EGR cooler clogging of power stroke

EGR cooler problems is also one of the most common Ford 6.7 Power Stroke problems. Not as common as the earlier 6.0 liter and 6.4 liter engines. Ford actually changed the design of the EGR system on the 6.7 liter engine. The valve is now on the hot side. EGR flows from the exhaust to the valve and then to the EGR cooler when the valve is open.

However, the new 6.7-liter Powerstroke design has its own problems. Carbon deposits can build up in the core of the EGR cooler and completely clog it. The good news is that replacing the EGR cooler is much easier than on previous Power Stroke engines. As with the EGT sensors, some 6.7-liter owners choose to bypass the EGR system.

Symptoms of a clogged EGR cooler

Look out for the following symptoms of problems with the Ford 6.7L Power Stroke EGR Cooler:

  • Error code P0401
  • Check the engine light
  • excessive heating

A Check Engine Light and DTC code P0401 indicate a likely problem with the EGR cooler. You may also notice overheating as the exhaust gas recirculation system may not cool the gases effectively if it is clogged.

Replacement PowerStroke EGR cooler 6.7 l

Once a problem arises with the EGR system, some choose to simply remove the entire system. EGR extinguisher kits are available for around $300-$400. However, this could cause problems in passing emissions tests in the future.

Otherwise, replacement is straightforward compared to previous Power Stroke engines. The EGR cooling kit for the 6.7L Powerstroke is around $200-$300. Advanced DIYers should have no problem disassembling the replacement EGR cooler. However, it may take a few hours for the process to complete.

3) PowerStroke 6.7 injection pump failure

Okay, that's our final topic, quite long. Let's speed things up in the next editions. Fuel Injection Pump (HPFP) failure can be a troubling issue for many 6.7L Power Stroke owners. This problem may be an exaggeration, but it's something to keep in mind. The HPFP is a Bosch CP4 and has been known to fail due to metal-to-metal contact within the pump. The concern is this: Metal contamination in the fuel system can carry many other components with it.

Some eventually had to replace a large portion of the fuel system when pump problems arose. Everything from the 6.7 Power Stroke injectors, regulators and fuel lines may need to be replaced. There have even been some class action lawsuits on these issues. Fortunately, Ford uses a new pump in the third-generation PowerStroke 6.7.

Symptoms of Power Stroke HPFP failure

Some symptoms of a Power Stroke 6.7 liter injection pump failure are:

(Video) Ford 6.7L Powerstroke Engine: Preventing Catastrophic Engine Failure

  • Pause
  • Long crank or no boot
  • Idling/stuttering
  • severe loss of energy

Once the pump fails, there will be a lack of fuel flow, which can lead to engine stalling. After shutting down, the engine may have starting problems and will not start. Inadequate fuel flow can also cause rough idling, stuttering and severe power loss. This is all assuming the 6.7 liter pump is still flowing with enough fuel to keep the engine running.

Ford 6.7L hp injection pump replacement

Some Powerstroke 6.7 owners say they spent over $10,000 to fix HPFP issues. This is because metal shavings from the pump damage many other components in the fuel system. Ultimately, in this scenario, almost the entire fuel system has to be replaced.

If you're lucky, you might be able to spot the problem quickly and prevent further damage. The pump can fail in ways other than metal-to-metal contact. In this case, the pump itself is still very expensive. You're lucky, however, as the entire 6.7-liter Powerstroke fuel system is best replaced.

4) Ford 6.7 Diesel V8 Radiator coolant leaks

We promised to speed things up a bit, and this is a pretty fundamental topic to discuss in 6.7 Power Stroke. There are a few other coolant leaks that can occur, but the radiator is among the most common. We should note that the 6.7 liter engine actually uses two radiators. The primary cooler is the most common problem.

We will skip the symptoms section as it is simple. Look for possible coolant leaks in front of the radiator. You may notice low coolant or overheating if the leak is severe enough or left alone for too long.

Ford PowerStroke 6.7 radiator replacement

An upgrade never hurts if the OEM cooler fails on the 6.7 PowerStroke. There are great options, but depending on the brand, it can cost twice as much as the OEM option. Ford's 6.7 engine uses an OEM CSF cooler and is typically available for less than $400.

The replacement is not very difficult, but is made a little more complicated by the use of two radiators. It takes some time and patience, but do-it-yourselfers should have no problem replacing the main radiator on the 6.7-litre diesel.

5) Ford PowerStroke 6.7L turbocharger issues

Turbo issues mainly affect first-generation 6.7-liter power-stroke diesel engines. Occasionally, the turbo bearing fails. Many suspect the failures to be due to Ford choosing a turbo that was undersized for the thrust and torque requested. Therefore, for those planning to modify their 6.7-liter Power Strokes for more power, failure can happen much sooner.

The second generation gets a larger upgraded turbo to boost horsepower and torque. Turbo misfire seems less common on these late 6.7 models. However, a turbo is heavily used in the course of its life. This is especially true for turbo diesel engines like the 6.7 liter PowerStroke as they generally have a very long lifespan. Modern turbos can usually outlast an engine's life, but that's not always the case with diesel engines, which can run well in excess of 200,000 miles.

(Video) 6.7 Powerstroke Best Year

It's not fair to call it a common problem when the turbo reaches the end of its natural lifespan. However, the point remains. Turbos are wearing parts and can fail with every Power Stroke of the 6.7 generation. Turbo life can also be significantly reduced on modified 6.7 liter engines.

6.7L Turbo Failure Symptoms

Look out for the following symptoms that could indicate a problem with your 6.7L PowerStroke Turbo:

  • excessive smoke
  • Oil/oil leak in the exhaust
  • Turbo does not reach target thrust
  • roaring turbo noise
  • power loss

When a turbo suddenly fails, it usually squirts some oil out of the exhaust, causing oil leakage and excessive smoke. We had sudden turbo failure on one of our gas powered cars and it was quite dramatic. Also look out for any unusual turbo noise or howling. Below target boost pressure and loss of power can also indicate that the turbo is dying and shutting down.

6.7 Replacing the power stroke turbo

The exact replacement depends on the generation of the 6.7 liter Powerstroke engine. However, replacing the turbo often costs over $2,000. Some opt for an upgraded turbo when the OEM turbo fails. Even if you're not looking for the extra horsepower, a bigger turbo will take less abuse and should last better in the long run. The downside, of course, is the slower turbo spool if you're using a really big turbo.

6.7 Is Power Stroke possible?

Yes and no. The Ford 6.7 liter engine certainly has some issues, particularly the first generation example. The second generation 6.7 engines are an improvement but still have some issues. We suspect the same case for the 3rd gen, but it's too new an engine to say positively. That's not to say the 6.7-liter Power Stroke engine is a terrible, unreliable engine.

Many of the problems stem from emissions-related components, which rules out some when problems arise. There are some things we didn't mention like SCR and DEF. Of course, legal aspects have to be considered when excluding OEM emission kits. However, with the exception of some of these emissions systems, these 6.7 liter engines certainly perform better and more reliably.

The 6.7-liter Power Stroke has a few other non-emissions issues. HPFP issues in particular can be a cause for concern due to the extensive damage that can occur. Primary coolers are known to leak as they age, and turbos can be problematic on early 6.7 liter engines.

6.7 Summary of Common PowerStroke Issues

Ford's 6.7-litre Power Stroke might not be the most reliable of diesels, especially when compared to some older diesels. Part of this is the nature of the plant's advanced emissions equipment. Ford isn't alone in struggling with some of these newer, more complex emissions issues. EGT sensors and clogged EGR coolers are among the most common problems with the 6.7 PowerStroke.

These systems (along with some other emission systems) can be bypassed and the 6.7 liter engine becomes much more reliable. However, in addition to the exclusion of these systems, there are also emission-related and legal concerns. If not, look for possible fuel injection pump problems as failure can quickly become catastrophic. Radiators are another common problem, and early 6.7-liter Power Strokes models occasionally experience turbo issues.

(Video) What to look for when buying a USED FORD 6.7 DIESEL | WATCH THIS & purchase SMARTLY!! |

Take away the exhaust systems and the 6.7 Powerstroke is a very reliable engine. Even with the few usual issues, the 6.7-liter Power Stroke should last over 250,000 miles. Maintain your Ford 6.7 liter engine well and you will most likely be rewarded with a great overall experience.

What is your experience with the Ford 6.7L PowerStroke? Are you thinking of buying one?
Leave a comment and tell us!


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