5 Common Ford 6.7 Diesel Problems

Are you worried about Ford 6.7 Powerstroke diesel engine problems? You’re not alone. Many truck owners love the power of this engine but wonder about its reliability.

The Ford 6.7 Powerstroke diesel has some known issues, but most can be fixed or prevented with proper care. From turbo troubles to fuel system glitches, we’ll cover the most common problems you might face.

Stick around to learn about these issues and how to keep your truck running strong. With the right know-how, you can enjoy the power of your Ford Powerstroke for years to come.

Overview of the 6.7 Powerstroke Diesel Engine

Ford introduced the 6.7 Powerstroke diesel engine in 2011. This powerful V8 engine was designed for Ford’s Super Duty truck lineup, including the F-250 and F-350 models.

The 6.7 Powerstroke comes in two main generations. The 1st gen was produced from 2011 to 2014, while the 2nd gen started in 2015 and continues today.

You’ll find impressive horsepower and torque ratings in this engine. The 1st gen offered up to 400 hp and 800 lb-ft of torque. The 2nd gen bumped those numbers up even higher.

Here are some key features of the 6.7 Powerstroke:

  • Turbocharged
  • V8 configuration
  • 6.7-liter displacement
  • Diesel fuel

Ford designed this engine in-house, moving away from previous partnerships. This allowed them to tailor the engine specifically for their Super Duty trucks.

The 6.7 Powerstroke aims to provide the power you need for tough jobs. Whether you’re towing heavy loads or navigating rough terrain, this engine is built to handle it.

Common Issues with the Ford 6.7 Diesel Engine

The Ford 6.7 diesel engine has some recurring problems you should know about. These issues can affect different systems in the engine.

Fuel System Challenges

Your 6.7 Powerstroke might face CP4 injection pump failures. This pump can wear out faster than expected. When it fails, metal shavings can get into the fuel system. This causes damage to other parts.

You might notice:

  • Loss of power
  • Hard starting
  • Engine stalling

To protect your engine, you can:

  • Use high-quality diesel fuel
  • Change fuel filters regularly
  • Install a lift pump

EGR System Complications

The EGR (Exhaust Gas Recirculation) system can give you headaches. EGR cooler clogs are common in early models. This part helps reduce emissions, but it can get blocked.

Signs of EGR trouble:

  • White smoke from exhaust
  • Coolant loss
  • Engine overheating

Regular cleaning of the EGR system can help. You might also consider an EGR delete, but check local laws first.

Turbocharger Troubles

Your truck’s turbo might act up, especially in older 6.7 Powerstroke engines. Turbo failures can happen due to oil contamination or bearing wear.

Watch out for:

  • Loud whistling noises
  • Loss of power
  • Excessive exhaust smoke

Regular oil changes with the right oil can help your turbo last longer. If you hear strange noises, get it checked right away.

Cooling System Contingencies

Your 6.7’s cooling system isn’t perfect. Radiator leaks can pop up, leading to coolant loss. The water pump might also fail over time.

Keep an eye out for:

  • Coolant puddles under your truck
  • Engine overheating
  • Sweet smell from the engine bay

Check your coolant levels often. If you spot any leaks, fix them fast to avoid bigger problems.

Sensor Sensitivities

Your 6.7 Powerstroke has many sensors that can act up. EGT sensors are known to fail in some models. When they do, your engine might lose power or run roughly.

Other sensor issues can include:

  • Faulty oil pressure sensors
  • Malfunctioning NOx sensors
  • Problematic fuel pressure sensors

Regular scans can catch sensor problems early. Don’t ignore check engine lights, as they often point to sensor issues.

The Fuel Delivery’s Weak Points

The 6.7 Powerstroke diesel engine has some issues with its fuel system. You should know about two main problem areas that can cause headaches for owners.

CP4 Injection Pump Failures

The CP4 injection pump is a major weak spot in the 6.7 Powerstroke’s fuel system. This pump has a high failure rate and can leave you stranded. When it fails, it often spreads metal bits through the whole fuel system.

Signs of CP4 pump trouble include:

  • Rough idling
  • Loss of power
  • Engine misfires
  • Metal shavings in the fuel filter

The damage from a failed CP4 pump can be costly to fix. You might need to replace fuel injectors, lines, and other parts. Some owners have even filed lawsuits against Ford over these problems.

Injectors and Fuel Contamination

Your 6.7 Powerstroke’s fuel injectors can also cause issues. They’re sensitive to contamination and can fail if dirty fuel gets in. Bad fuel quality or a faulty CP4 pump can lead to injector problems.

Watch out for these symptoms:

  • Poor engine performance
  • Rough running
  • Decreased fuel economy
  • Check engine light coming on

To protect your injectors, use good quality diesel fuel and change your fuel filter regularly. If your CP4 pump fails, have a mechanic check the injectors for damage right away.

Keeping an eye on your fuel system can help you catch problems early. This may save you from bigger, more expensive repairs down the road.

Turbocharger and Airflow Issues

The Ford 6.7 diesel engine often faces problems with its turbocharger and air management system. These issues can impact performance and lead to costly repairs if not addressed quickly.

Turbo Issues and Limp Mode

If you own a Ford 6.7 Powerstroke, you might experience turbo failures, especially in 2011 and 2012 models. The early Honeywell DualBoost turbos used ceramic bearings, which were prone to breaking. You may notice a whining noise or loss of power, especially at higher RPMs.

When turbo problems occur, your truck might enter limp mode to protect the engine. This limits your speed and power output. If you’re towing heavy loads, you’ll feel a significant drop in performance.

Ford fixed this issue in later models by switching to steel ball bearings. If you have an older model, upgrading to a newer turbo design could prevent future failures.

Air Management and Carbon Deposits

Your 6.7 Powerstroke’s air management system can also cause trouble. The variable geometry turbocharger (VGT) might wear out faster if you do a lot of heavy towing.

Carbon deposits can build up in the intake system over time. This happens when oil and fuel residue mix with exhaust gases. You might notice:

• Reduced fuel efficiency
• Rough idling
• Loss of power

Regular cleaning of your intake system can help prevent these issues. Using high-quality fuel and oil can also reduce carbon buildup. If you’re experiencing these problems, it’s best to have a mechanic check your engine soon.

Exhaust Gas Recirculation Challenges

The Ford 6.7 Powerstroke diesel engine faces some tricky issues with its exhaust gas recirculation (EGR) system. You’ll want to keep an eye out for problems with the EGR cooler and valve that can impact your truck’s performance.

EGR Cooler Issues

Your 6.7 Powerstroke’s EGR cooler plays a big role in keeping things running smoothly. But it can run into trouble. Severe soot buildup is a common headache for these coolers. This gunk can clog up the works and hurt your engine’s efficiency.

The cooler might also spring a leak. If this happens, you could see:

  • Coolant loss
  • White smoke from the exhaust
  • Engine overheating

To avoid these issues, regular cleaning of your EGR system is key. You might also think about installing an EGR delete kit, but be aware this can affect emissions and may not be legal in all areas.

EGR Valve and Leakage Problems

Your EGR valve can cause just as much trouble as the cooler. A sticky or clogged valve might lead to:

  • Poor fuel economy
  • Rough idling
  • Failed emissions tests

Ford changed the EGR design in the 6.7L engine, putting the valve on the hot side. This new setup can cause more clogging than in older models.

Leaks around the EGR valve are another worry. You might notice a hissing sound or feel a loss of power. Regular checks and cleaning can help catch these problems early. If you spot any issues, it’s best to get them fixed quickly to avoid bigger headaches down the road.

Cooling System and Overheating

The Ford 6.7 diesel engine can face cooling issues that may lead to overheating. These problems often stem from radiator leaks and faulty components like water pumps and thermostats.

Radiator Leaks and Prevention

Radiator leaks are a common 6.7 Powerstroke problem. You might notice coolant puddles under your truck or see the temperature gauge creeping up. To prevent leaks, check your coolant levels regularly and look for any signs of damage on the radiator.

Consider using a high-quality coolant and flushing the system as recommended by Ford. If you spot a small leak, a radiator sealant might offer a temporary fix. For larger leaks, you’ll need to replace the radiator.

Keep an eye on your coolant temperature gauge while driving, especially when towing heavy loads. If you see it rising quickly, pull over safely and let the engine cool down.

Water Pump and Thermostat Faults

Your 6.7 diesel’s water pump plays a crucial role in circulating coolant. If it fails, your engine can overheat rapidly. Signs of a failing water pump include:

  • Coolant leaks near the front of the engine
  • Squealing noises from the front of the engine
  • Sudden temperature spikes

The thermostat can also cause overheating if it gets stuck closed. You might notice your truck takes longer to warm up or overheats quickly.

Regular maintenance can help prevent these issues. Have your cooling system inspected annually, and replace the water pump and thermostat as recommended by Ford or if you notice any problems.

Sensor Technology and Failures

Ford’s 6.7 diesel engines rely on various sensors to monitor performance. Some sensors have had reliability issues, causing problems for truck owners.

EGT Sensor Failures

EGT sensor failures are a common headache for 6.7 Powerstroke owners. Your engine uses 4 exhaust gas temperature (EGT) sensors, giving plenty of chances for things to go wrong. When these sensors fail, you might notice:

• Check engine light coming on
• Reduced engine power
• Poor fuel economy

Ford extended the warranty on EGT sensors due to frequent issues. If you’re having EGT problems, check if you’re covered. Replacing faulty sensors usually fixes the problem.

Other Sensor Reliability Issues

Your 6.7 Powerstroke has other sensors that can act up too. The MAP sensor is known to fail repeatedly in some trucks. Signs of a bad MAP sensor include:

• “Reduced Engine Power” warnings
• Check engine light
• Poor performance

NOx sensors were another trouble spot, especially in 2011 models. These measure exhaust emissions. Failed NOx sensors can trigger check engine lights and affect your truck’s performance.

Regular maintenance and prompt attention to warning signs can help you catch sensor issues early. This can save you from bigger headaches down the road.

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  • I'm the founder of Daily Car Tips. I wrote articles in the automotive industry for more than 10 years, published in USA and Europe. I love sharing my knowledge and insights with fellow enthusiasts. Join me on this journey as we explore the exciting world of cars together!

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