Even if it could, the new common rail diesels being used by their competitors were beating Ford in performance. While the 7.3l was famously reliable, Ford and Navistar knew it wouldn’t be able to reach upcoming NOx emissions requirements. Upgrading to head studs should address this problem.įord 6.0 Powerstroke Problems (2003-2007)
6.0 powerstroke oil in coolant reservoir crack#
Our replacement water pumps have a billet aluminum impeller that won’t crack.Ĭooling system: The factory radiators tend to crack and separate where the plastic tanks meet the aluminum core.Ĭylinder head: Like the 6.0l, the head bolts used on this engine may not provide enough clamping force to protect the head gasket. Water pump: The stock pump’s plastic impeller has the same cracking issues as the one used in the 6.0l. We also offer a supplemental cooler, which adds more cooling capacity to the oil cooling system and improves the filtration system as well. Our remote cooler mounts below the brake booster, allowing you to flush or replace the oil cooler easily, once the kit is installed. We offer two ways to address this problem. This cooler is buried under the intake manifold and turbo system, which means it is very difficult and costly to replace. Oil cooler: Debris in the oil or coolant can clog the cooler, leading to increased oil temperatures. As a result, the horizontal cooler tends to fail before the vertical cooler. Exhaust enters the horizontally-mounted cooler first, so it experiences more heat than the vertical cooler. However, these coolers are still prone to cracking. This dilutes the oil, which may make it less effective at lubricating the engine.ĮGR cooler: To address the EGR cooler failures of the 6.0l, Navistar added a second cooler to spread out the thermal load. The process also forces diesel into the crankcase. This hampers performance and increases temperatures across the engine. Over time, this filter can become permanently clogged, forcing the engine to stay in regen mode and eventually requiring replacement. During regen, power and fuel economy drops while exhaust temperatures increase. Once the filter is full, the engine goes into regen mode, spraying diesel during the exhaust stroke to burn off this soot. For this reason, addressing 6.4 Powerstroke problems by upgrading failure-prone components may result in larger cost savings over the vehicle’s life than any other model on this list.ĭiesel particulate system: The particulate filter captures soot from the exhaust gas. This adds several hours of labor to repairs, making parts replacement far more costly on the 6.4l than other Powerstrokes. Many engine components can only be accessed by lifting the cab. These problems are compounded by the design of the truck. While the 6.4l did address some of its predecessor’s problems, it also added new ones. Tuners quickly found ways to increase power with just a few ECU programming changes, while commercial owners appreciated the stock engine’s overall improvement in power and fuel economy. However, a better oil cooler may still help with keeping oil temperatures under control.įord 6.4 Powerstroke Problems (2008 – 2010)Įarly on, the 6.4l liter promised to address most of the problems with the 6.0l, while offering better overall performance. Oil cooler: The cooler used in these engines is less fragile than those found in earlier Powerstrokes. EGT sensors are used by the ECU to monitor the catalytic converter and diesel particulate filter. Extreme exhaust temperatures can cause the sensor to strip the exhaust bung during removal, requiring retapping or replacement. This cooler still has the failure characteristics of most other factory coolers, in regards to overall expansion and contraction of the metal parts.Įxhaust system issues: Exhaust gas temperature (EGT) sensors fail so frequently that Ford extended the warranty on this part. This cooler design is a cartridge style as well, so when applicable the core or guts of the cooler can be changed, rather than the entire assembly. That said, there are still some common 6.7 Powerstroke problems you should watch out for.ĮGR Cooler: The redesign moved the EGR cooler to a location that makes it easier and less costly to replace. The result wasn’t just a better fit for heavy hauling and towing, it was also a major improvement in reliability. This includes reverse flow heads, valves with individual pushrods, and an air-to-water intercooler. Since this engine was built specifically for their trucks, the engineers were able to add new features that improved drivability and performance. Here’s some of the most common problems for each generation.įord 6.7 Powerstroke Problems (2011 – 2016)Īfter dealing with the problems of the Navistar-designed Powerstroke engines, Ford decided to develop the next Powerstroke in-house. Ford Powerstroke Problems Across Generations
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