6.7 Powerstroke Problems & Common Fixes
Even the dependable 6.7 Powerstroke has its own problems. From the “death wobble” that every truck owner is all too familiar with to CP4 Bosch pump failures that can cost you up to $9,000, we’ve listed the most common 6.7 Powerstroke issues and a solution next to them.
6.7 Powerstroke Turbo Problems
The Problem: Ceramic ball bearings on early 6.7 Powerstroke engines failed until Ford replaced them with steel bearings, as did the aluminum-alloy metal parts on later trucks.
Recommended Fix: There isn’t a quick fix for the problem. We recommend investing in a new aftermarket turbocharger.
Explanation: On the late ’11 and early ’12 model years of the 6.7 Powerstrokes, turbochargers have been an issue. They’re costly to replace due to their design. Even with performance modifications, the Garrett GT32 SST turbocharger is likely to fail. Once it goes, you’ll hear a horrible screaming noise coming from the engine compartment in addition to greasy smoke pouring out of the back of your car’s tailpipe
6.7 Powerstroke Fuel Filter Change Problems
The Problem: The replacement of the fuel system resulted in fuel entering the engine.
Recommended Fix: Turn the key on and off 5-6 times to cycle the fuel pump. Once the air has been removed from the system, you should hear a difference in sound.
Explanation: If the solution isn’t effective, you either attempted to start the truck after changing the filters without cycling or the system is improperly sealed (the air is still entering the system).
Remove the lower fuel filter and double-check that the O-ring hasn’t been sliced. Make sure all of the O-rings are correctly sealed in their grooves and tightened. Check both lines to be sure they’re snapped on correctly with the upper fuel filter. 5-6 times, turn on and then off with the key to test for leaks.
6.7 Powerstroke Transmission Problems
The Problem: Shift flairs are common in Powerstrokes with 6R140 transmissions, although this isn’t an issue unless the engine is heavily damaged or if the transmission seals have failed.
Recommended Fix: The solenoid/s may be replaced and the ECU reprogrammed if necessary to resolve the problem.
Explanation: The solution above should fix the problem, but if you’re having a more severe case, your transmission may need to be replaced entirely.
If you don’t address the problem, it will continue to deteriorate, and eventually the entire transmission will need to be replaced. It will break down since this isn’t a continuing problem, and many dealership services won’t repair it because of that.
6.7 Powerstroke Fuel Pump Problems
The Problem: The CP4 fuel pump will wear out and pollute the entire fuel system with metal shavings, causing the engine to fail. The CP4 fuel pump failure can result in total engine failure.
Recommended Fix: There is no one-size-fits-all solution, but diesel additives and a diesel disaster prevention kit can assist.
Explanation: Because the CP4 fuel pumps aren’t constructed to meet diesel fuel quality and lubrication standards required in the United States, they wear out prematurely. When the fuel pumps become dry, metal particles are generated as a result of metal rubbing against metal, producing slivers. Metal shavings enter the system (and in most cases the engine) causing it to fail without notice. Fuel additives help to keep the pump lubricated and a CP4 pump failure prevention kit protects the system from harm when the pump eventually fails.
6.7 Powerstroke Fan Clutch Problems
The Problem: At extremely hot temperatures, the fan clutch does not operate.
Recommended Fix: A worn-out fan clutch is most likely causing this problem.
Explanation: The fan clutches get old and worn down, necessitating a replacement. You’ll save approximately $500 if you perform the job yourself. If you want to replace the fan on your own, it will take you a few hours. In order to install it, you’ll also need a fan clutch tool.
6.7 Powerstroke Intercooler Pipe Problems
The Problem: The intercooler pipe is known to blow off under boost, especially on modified vehicles. Even in stock form, heat causes the plastic components to weaken, resulting in failure.
Recommended Fix: Examine the existing intercooler pipe for cracks, wear, or other damage. If it’s damaged, replace it. The installation should take less than 20 minutes.
Explanation: The intercooler pipe is likely to burst on the road when you’re driving with boost, and if you need immediate help, duct tape will come in handy. Because your truck loses all of its power rapidly, this may be a hazardous situation. To avoid danger, some 6.7 Powerstroke owners change their intercooler pipes before 100,000 miles.
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Conclusion
Although the 6.7L PowerStroke engine from Ford is not the most durable diesel engine, it may still have some issues. Modern emissions equipment on the factory-installed level is partly to blame. Ford isn’t alone in having problems with some of this more recent, sophisticated emissions technology. The 6.7L PowerStroke has a lot of EGT sensors and EGR coolers that clog over time.
Delete these systems (as well as some other emissions systems) and the 6.7L engine becomes far more dependable. However, there are legal and environmental issues associated with removing these systems. Otherwise, keep an eye out for potential concerns regarding the fuel injection pump failure, which may rapidly get out of hand. Another typical issue is the radiator, which early-production 6.7L Power Strokes can have problems with their turbochargers.
Take out the emissions systems, and the 6.7L Powerstroke is a highly dependable engine. Even with minor issues, the 6.7L Powerstroke should last 250,000 miles or more. Maintain your Ford 6.7L engine properly, and it will most certainly provide you with an enjoyable overall experience.
