Common Problems with Ford's 6.7L Powerstroke Diesel Engine and How to Fix Them

Ford's 6.7 Powerstroke diesel engine has been a popular choice for many truck owners since its introduction in 2011. Known for its power and reliability, this engine has been used extensively in Ford's F-series trucks. However, like any engine, the 6.7L Powerstroke has had its share of problems. In this blog post, we will discuss some of the common issues faced by owners, symptoms to help diagnose these failures, and ways to fix them, along with associated costs.

6.7 diesel turbo failure

The turbocharger in the 6.7L Powerstroke is prone to failure due to excessive soot buildup, resulting in reduced performance and premature VGT failure in the 2011-2014 models.

The turbo will let you know it's tapping out from poor acceleration, excessive smoke from the exhaust, a check engine light with DTC codes P2263 or P0299, or compressor surging noises, especially on deceleration.

To fix this problem, the turbocharger may need to be cleaned or replaced. Cleaning costs can range from $300 to $500, while a replacement turbocharger can cost between $1,500 and $2,500.

Ford F250 6.7 EGR valve and cooler failure

The EGR valve helps reduce emissions by recirculating a portion of the exhaust gas back into the engine. However, the valve can become clogged or damaged, leading to poor performance and increased emissions.

This isn't nearly the problem of the previous 6.0L Powerstroke, but it's still an issue on the 6.7L Powerstroke.

Failed EGR valves produce a rough idle, poor acceleration, decreased fuel efficiency, and a check engine light with DTC codes P0401 or P0402.

Cleaning the EGR valve can sometimes solve the issue and costs around $100 to $200. However, if the valve is damaged, it may need to be replaced, costing between $300 and $500.

EGR coolers become clogged leading to overheating and structural failure. Bulletproof diesel makes several parts for 6.7 Ford Powerstrokes, including an engine oil upgrade, a Bulletproof EGR cooler ($1100), and a Bulletproofed oil cooler ($330).

Ford diesel fuel injectors fail

Over time, fuel injectors become clogged or break with the high diesel line pressure causing poor engine performance (including misfire and smoke) and reduced fuel efficiency.

You'll an injector is failing from misfires, rough idle, poor acceleration, decreased fuel efficiency, and a check engine light with DTC codes P0200 or P0300.

Cleaning the injectors rarely resolves the issue, costing around $150 to $300. Replacement is typical between $1,500 and $3,000 for a full set.

Cracked 6.7 exhaust manifold

6.7s are infamous for cracked manifolds. Cracks in the manifold can cause exhaust leaks, leading to poor performance and increased emissions. Ticking noise during acceleration, poor engine performance, and a check engine light with DTC codes P0420 or P0430.

The only solution for a cracked exhaust manifold is replacement, which can cost between $1,000 and $1,500.

While the 6.7L Powerstroke diesel engine is known for its power and reliability, owners should be aware of these common problems. Regular maintenance can help prevent many of these issues, but it is crucial to diagnose and fix them promptly to avoid further damage.

Overall, the Ford 6.7L Powerstroke diesel engine is a solid choice for truck owners looking for power, towing capacity, and fuel efficiency. However, owners need to be vigilant about maintenance and watch for potential problems. With proper care, the 6.7L Powerstroke can provide years of reliable service. It is essential to weigh the pros and cons before making a decision, keeping in mind the potential costs associated with some of the common problems. Despite these issues, many owners find that the benefits of owning a truck with the 6.7L Powerstroke diesel engine outweigh the drawbacks.

If you are considering a Ford truck with a 6.7L Powerstroke diesel engine, it is important to be aware of the potential problems and associated costs. Regular maintenance and timely repairs can help keep your engine running smoothly and extend its lifespan. By being proactive and informed, you can enjoy the power and performance of your 6.7L Powerstroke while minimizing any potential issues.