Troubleshooting 6.7 Powerstroke Problems: Common Issues and Solutions

Nov 13, 2023

Ford’s 6.7 Powerstroke engine marked the manufacturer’s first foray into designing their own diesel engines. While the diesel engine has been a popular choice since its debut, particularly among Ford enthusiasts, there’s been no shortage of 6.7 Powerstroke problems.

Whether you currently own a 6.7 Powerstroke engine or you’re considering buying one, you should be aware of the most common 6.7 Powerstroke problems and what to do if your trusty Ford turns out to be a lemon.


Understanding the Ford 6.7 Powerstroke Engine

The advent of Ford’s 6.7 Powerstroke diesel engine was heralded as a success for the popular American car manufacturer. Ford moved diesel engine production in-house after issues with its previous 6.0 and 6.4 diesel engines. The resulting 6.7 Powerstroke was released and was initially met with praise.

However, after over a decade on the market, an alarming number of 6.7 Powerstroke problems have been plaguing owners of Ford’s powerful diesel engine.

Features and Specifications of the 6.7 Powerstroke Engine

The 6.7 Powerstroke is widely regarded as a powerful, dependable diesel engine. It’s long been a popular choice among American truck owners, primarily due to the 6.7 Powerstroke specs. Some general 6.7 Powerstroke engine specifications for 2020–2023 include:

  • 35,000-lbs maximum towing capability
  • 475 peak horsepower
  • 1,050 lbs-ft torque
  • 7,640-lbs maximum payload
  • 4×4 drive system

Engine specs vary by style. Ford’s most powerful truck, the 2023 Super Duty pickup, boasts a 6.7 Powerstroke horsepower of 500 and 1,200 lbs-ft torque.

Benefits and Drawbacks Compared to Other Engines

Aside from the 6.7 Powerstroke’s impressive performance, Ford’s decision to bring the diesel engine production in-house is another benefit that Ford fans have hailed as an intelligent decision. That is especially true in light of the many issues associated with the Ford diesel engine models that preceded the 6.7 Powerstroke.

Most truck enthusiasts are quick to pit Ford’s 6.7 Powerstroke vs. 6.7 Cummins with RAM. Both offer turbocharged diesel engines with four valves per cylinder. One of the chief differences between the two popular engines is horsepower vs. torque.

Ford offers a slightly higher horsepower — roughly 450 hp compared to RAM’s 400 hp. At the same time, RAM edges out Ford in terms of torque. The 6.7 Cummins engine boasts 1000 lbs-ft torque, while the 6.7 Powerstroke lags slightly behind at 397 lbs-ft torque for most models.

One of the most significant benefits of the Ford engine is its outstanding warranty. The 6.7 Powerstroke warranty extends for either five years or 100,000 miles. This generous period is good news for owners of the 6.7 Powerstroke crate engine, as increasingly frequent 6.7 Powerstroke problems mean there’s a good chance owners may need to make use of the warranty.


Common 6.7 Powerstroke Problems

Despite its popularity, the 6.7 Powerstroke faces no shortage of issues. From fuel pump failure to coolant leaks, owners have ample reasons for frustration regarding reliable performance. If you own a 6.7 Powerstroke, you should know the most common issues with Ford’s diesel engine.

High-Pressure Fuel Pump Failure Symptoms

6.7 Powerstroke high-pressure fuel pump failure symptoms indicate one of the most expensive issues a Ford diesel engine owner can encounter. Some of the primary signs your fuel pump is failing include:

  • Low power output
  • Engine stopping suddenly
  • Acceleration doesn’t stay constant
  • Filter needs to be changed after a few days
  • Fuel pump valves won’t open
  • Air conditioner doesn’t work properly
  • Unusual noises from the engine
  • Low mileage per gallon

Replacing your high-pressure fuel pump is no small job, either. After consulting your 6.7 Powerstroke engine diagram, you’ll see that the replacement pump you need can cost well over $1,000, not including labor costs.

Keeping your Ford 6.7 Powerstroke fully functional depends on proper maintenance. Changing the filter regularly and using the correct fuel can help reduce the risk of experiencing fuel pump failure symptoms.

Exhaust Gas Temperature (EGT) Sensor Failure

The 6.7 Powerstroke emission after-treatment system includes multiple EGT sensors, which have been known to fail on specific Ford models equipped with diesel engines. When EGT sensors fail, the truck’s engine may shut down suddenly while driving and might not restart after an unexpected shutdown.

6.7 Diesel EGR Cooler Clogging Issue

EGR refers to the engine’s exhaust gas recirculation valve. The EGR controls carbon emissions and regulates the combustion chamber temperature.

Diesel emissions run the risk of interfering with EGR valve performance. In the 6.7 Powerstroke, emissions from the diesel gas stick to the EGR valve. As a result, the valve’s ability to regulate combustion chamber temperature is compromised, leaving the engine at risk of overheating.

Ford Diesel Engine Radiator Coolant Leaks

Another known issue with Ford’s 6.7 Powerstroke is the high frequency of radiator coolant leaks. These leaks are prevalent on the driver’s side of the engine. Owners can check for leaks in the metal crimps and drain petcock. Leaks or low coolant levels indicate that your engine might be at risk of overheating.

If you notice a leak but your radiator coolant levels look normal, it’s worth noting that the 6.7 Powerstroke has also been known to leak coolant at the water pump and the turbo coolant fittings.

Injection Pump Failure

Your engine’s injection pump regulates how much fuel is sent to the engine. Injection pump failure is a well-documented concern with Ford’s 6.7 Powerstroke.

When your injection pump fails, debris can spread throughout your engine’s entire fuel system, leading to an expensive trip to the mechanic. Dealing with an injection pump failure involves cleaning the whole fuel system and replacing the fuel injection pump, fuel injectors, and pressure regulators.

Tips for Minimizing Engine Replacement Expenses

The 6.7 Powerstroke engine replacement cost is substantial.

Estimates for a new one range from $10,000 to $13,000. However, that price doesn’t include labor or other parts that may also need replacing, depending on your specific issue. An engine replacement is labor-intensive, meaning labor costs will likely cost several thousand more.

If replacing your 6.7 Powerstroke engine is unavoidable, you can cut costs using a used engine instead of a new one. Depending on the condition and mileage, opting for an engine rebuild with a pre-used engine can cut your cost nearly in half, especially if you negotiate the price with your mechanic.

The best way to minimize engine replacement costs is through proper maintenance. Having your truck serviced regularly, using the correct fuel and oil, and seeing a mechanic as soon as you notice an issue can help catch minor problems before they become major ones.


6.7 Powerstroke Years to Avoid

The 6.7 Powerstroke has been on the market for over a decade. At that time, Ford released three generations of the same diesel model.

Before you opt for a different Ford diesel engine, it’s best to do your research. The 6.7 Powerstroke is by no means the only Ford diesel engine to have issues — the 6.0 and 6.4 also have many problems, and there are several 7.3 Powerstroke years to avoid as well.

Critical Issues with Specific Models of the 6.7 Powerstroke Engine

Each year of the 6.7 Powerstroke is susceptible to specific issues. The second generation includes models through 2019, while the third generation includes models from 2020 and later.

Specific issues to watch for based on the release date include:

  • Second generation: radiator, coolant, oil leaks, glow plugs, and turbocharger
  • Third generation: EGR cooler

The biggest issue with the most recent generation pertains to the engine’s EGR cooler. That is one issue that Ford made no effort to resolve with the release of the third-generation engine. And new models remain at risk of the same problems with second-generation engines.

Factors to Consider When Purchasing a Used 6.7 Powerstroke

Generally speaking, the older a Powerstroke is, the more likely it is to have a documented history of issues. However, the year alone doesn’t count when identifying potential problems.

It’s also true that the older a model is, the more likely it is that the owner has run up the mileage on it. Unfortunately, that can mean that only time will tell what major issues Ford’s most recent models may present. When purchasing a used 6.7 Powerstroke, consider the truck’s history, including accidents, maintenance, and repairs.


Do You Have 6.7 Powerstroke Problems? Timothy Abeel Can Help

If you’re having issues with a Ford 6.7 Powerstroke, Timothy Abeel & Associates can help. Our firm offers legal support with under-warranty vehicles in multiple states, including Arizona, California, Florida, New Jersey, Ohio, Pennsylvania, Texas, and West Virginia.

Litigate Lemon Law and Breach of Warranty

Lemon law offers legal recourse to consumers who have purchased or leased faulty vehicles. You shouldn’t have to pay for Ford’s 6.7 Powerstroke manufacturing defects. Timothy Abeel & Associates can help you recover compensation under either lemon law or breach-of-warranty claims with our California lemon law lawyers

Legal Fees and Costs

Car issues are expensive, but your lawyer doesn’t have to be. We have recovered millions of dollars for our clients and settled most cases in 30-90 days. At Timothy Abeel & Associates, we work strictly on a contingency basis. That means you only pay if we win your case.

We represent your side and work with no expense to you — no out-of-pocket costs, win or lose. Contact Timothy Abeel & Associates today to learn more about how to take legal action over a defective Ford 6.7 Powerstroke diesel engine.

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