What Are the 5 Most Common Ford 6.7 Diesel Problems to Know About?

They say that Americans love their trucks regardless of soaring gas prices. What’s not to love? Pickup trucks are powerful enough for off-roading and loading heavy cargo while maintaining comfort and a smooth ride. 

When your new pickup truck fails to perform the way it was meant, you may be looking for answers. The 6.7L diesel engine, also known as the PowerStroke, has had a multitude of problems since its introduction into Ford’s Super Duty series. If you own a Ford pickup truck equipped with the PowerStroke and have experienced the following issues, you may be entitled to compensation under your state’s lemon laws. 

What is the 6.7 PowerStroke Diesel Engine? 

According to Experian, pickup trucks are the most common American vehicle in operation, with one-fifth of the market share and 16.5% of new vehicle registrations. Known for its toughness and reliability, the Ford PowerStroke diesel engine is a popular choice for Super Duty superiority.

From towing power to horsepower, it is a beast when it comes to pickup trucks.

Key specifications include:

  • 450 HP
  • 935 lb.-ft. torque
  • 4×2 or 4×4 drive system
  • 35,000 lbs. max towing
  • 7,640 lbs. max payload

Plus, it comes with a “TorqShift® heavy-duty 6-speed SelectShift™ automatic transmission.”

Key engine features include:

  • 157-amp standard
  • 332-amp dual alternators optional
  • Stationary elevated idle control
  • Pressurized series flow cooling system
  • Aluminum cylinder head
  • Compacted graphite iron block material
  • Push rod/rocker arms valve operation

The 6.7L is in its third generation, which was introduced into the market in 2020. 

Ford’s PowerStroke Engine has a Long History of Issues

Ford began designing and producing their own diesel engines in 2011 with the introduction of the 6.7 L Power Stroke. Prior to the PowerStroke, Navistar International designed and produced all Ford engines.

While the power stroke engines have been hailed as one of the most reliable diesel engines on the market, they have a long history of issues. Some of the most common engine problems consumers have reported involve:

  • Stalling or no-starting due to a faulty camshaft position sensor (CPS)
  • Frequent fuel leaks due to cracks in the aluminum housing
  • Heating elements shorting out and causing the engine not to start
  • Leaky turbocharger pipes
  • Defective exhaust back-pressure valves

While the third generation has seen improvements over the first- and second-generation predecessors, there are challenges to be aware of if you purchase a Ford with a 6.7 diesel engine.

Exhaust Gas Temperature (EGT) Sensor Failure

Designed to communicate the engine’s exhaust gas temperature, the PowerStroke has four sensors. This means four times the possibility of failing. Ford initially gave an extension on the warranty coverage for these sensors.

It is the middle two sensors that have the highest incidents of failure. If the extended warranty covers your vehicle, a dealer should repair the problem. 

If you have an EGT sensor failure, a common sign would be:

  • Check engine light
  • “DTC” fault codes flashing
  • Failed emissions test

Many trucks now have PCM updates which would trigger the “check engine” light instead.

The bright side is that these sensors are easy to access and replace, typically running between $35 to $50 each. First, you want to determine which sensor you have that is bad. Then, you can find it along with the exhaust manifold.

If you plan to fix it yourself, make sure that the engine is cool before trying to fix it.

6.7 Diesel EGR Cooler Clogging Issues

The exhaust gas recirculation (EGR Cooler) reduces the combustion chamber temperature. When the valve opens, it begins to cool the exhaust as it moves from the manifold and is reintroduced into the intake of the engine. However, when carbon deposits collect on the core of the cooler, it can lead to a clog.

The most common signs of an EGR cooler clog involve:

  • Check engine light is on
  • You get a DTC code
  • Rough idle
  • Poor performance
  • Stalling
  • Smelling like fuel
  • PowerStroke engine overheating

Illegally deleting the system will only create problems with your emissions test. Call your dealer to replace the EGR sensor. 

Ford Diesel Engine Radiator Coolant Leaks

Radiator coolant leaks are common with the 6.7L diesel engine. While the PowerStroke has two radiators, the primary one is the most likely to present with a leaking issue. Overheating or low coolant are signs of a bad leak. 

Having two radiators complicates replacement, making it more labor intensive than other vehicles. Parts alone typically will average around $400. 

Injection Pump Failure Leads to Numerous Potential Problems

A vehicle’s injection pump functions similarly to a heart. Our hearts pump faster when we exercise to give our muscles the oxygen they need to perform better. Likewise, the injection pump delivers fuel to the engine based on the power needs of the vehicle. 

In the 6.7 diesel engines, the pumps lack adequate lubrication and causes metal to rub against metal. Fragments then make their way into the injection systems and engine. Metal contamination can damage the fuel system, lines, injectors, and regulators.

Some symptoms of injection pump failure or metal contamination can include:

  • Lengthy crank times
  • Stalling
  • Sudden and severe loss of power
  • Stuttering and a shaky idle

When metal fragments contaminate a 6.7 diesel engine, multiple components can fail. In most cases, the entire fuel system must be replaced. 

6.7L Diesel Engines Turbocharger Issues 

Turbochargers have been known to fail in 6.7L diesel engines. In many cases, the turbo bearings cause engine failure. Turbo bearings are engine components that ensure the correct parts rotate and reduces friction. However, consumers have alleged that Ford’s turbo is too small to maintain lubrication and spin correctly. 

Common symptoms of turbo failure in a 6.7 diesel engine include:

  • Loss of power 
  • Whining or screeching sounds from the engine
  • Excessive smoking
  • Oil in the exhaust or oil loss
  • Lack of pressurized air being pumped into the engine (i.e., target boost)

A turbo’s sudden failure will result in a substantial amount of oil being dumped into the exhaust. Clouds of billowing dark smoke will erupt. Replacing a failing turbo is expensive. If your turbo in Ford’s 6.47 diesel engine has failed before its time, call your dealer to express your concerns immediately. 

What Vehicles Have the Ford 6.7 Diesel Engine? 

The 6.7 diesel engine was released in 2011 and is in several of Ford’s pickup trucks. Most notably, Ford Motor Company has equipped their line of F Series Super Duty pickup trucks with their in-house power stroke diesel engine.

Models include:

  • F-150 XLT
  • F-150 Lariat
  • F-150 Platinum
  • F-150 King Ranch
  • F-250
  • F-350
  • F-450

If you drive a Ford pickup truck with a 6.7L diesel engine and have experienced issues, contact the lemon law attorneys of Robinson Lemon Law Group for a free case evaluation. 

Has a Recall Been Issued for Ford Trucks Equipped with 6.7 Diesel Engines?

Ford is recalling many of its Super Duty trucks outfitted with the 6.7 power stroke diesel engines. According to reports, a washer in the truck’s transmission can fragment and disintegrate. Small metal particles can become lodged in the parking mechanism and prevent the truck from fully entering the park position. The pickup truck could roll away while the shifter is locked in park mode. 

Do You Have Ford 6.7 Diesel Problems?

With Robison Lemon Law Group LLC, we help our clients litigate Lemon Law and Breach of Warranty cases. No matter your situation, we will evaluate your case at no cost and no obligation

Depending on your particular set of circumstances, we can submit a claim to the manufacturer or file suit immediately. Our lemon law attorneys will represent your best interests and aggressively advocate on your behalf. 

The manufacturer must pay the legal fees and costs per the Lemon Law and Breach of Warranty. You have nothing to lose. You have everything to gain. Schedule a free consultation today to learn more about PA Lemon LawNY Lemon Law, or NJ Lemon Law. Discover your options if you have Ford 6.7 diesel problems.

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