3 Most Common Ford 6.7 Diesel Problems to Know About

They say that Americans are in love with their trucks, even when gas prices are soaring. According to Experian, pickup trucks are the most common American vehicle in operation, with one-fifth of the share in the market, and 16.5% of new vehicle registrations.

You may love pickup trucks, but you will not adore one that comes with common issues and repairs, like the Ford 6.7 diesel problems. If you are not aware of what these issues are, don’t worry. This article will get to the bottom of it.

Now, here is more detail on PowerStroke engines and the three most common Ford 6.7 diesel problems.

6.7 PowerStroke Specs and Info

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.

As a matter of fact, Ford themselves likes to boast their slogan, “Built to Last.”

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. While the third generation has seen improvements over the first- and second-generation predecessors, there are challenges to be aware of when you purchase this truck.

1. EGT Sensor Failures

Designed to communicate the exhaust gas temperature of the engine, the PowerStroke has four sensors. This means four times the possibility of failing, as this is common. Ford had originally given 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 will take care of it for you.

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

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

If one sensor fails, the truck can go limp. Many trucks now have PCM updates which would trigger the “check engine” light instead.

There is a bright side in that these sensors are simple to access and easy to 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.

2. EGR Cooler Clogs

The EGR Cooler cools the EGR flow, so it is a lot like how it sounds. It starts from the exhaust to the valve. It will monitor the flow of the exhaust.

When the valve opens, it begins to cool. What happens is that the carbon deposits will collect on the core of the cooler. This leads to a clog.

The second of the most common PowerStroke problems, the good news is that these are easy to replace, like the sensors.

Signs that you have an EGR cooler clog include:

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

Some people choose to delete the system, but it will only create problems with your emissions test, and it is illegal. You are much better off replacing it. An EGR sensor will typically cost about $100.

3. Radiator Coolant Leaks

The Ford 6.7 PowerStroke will use two radiators, but it is the primary one that is known for leaking. It is easy to detect, and you could DIY to fix it.

OEM replacements are about $400. You could consider an upgrade to an aftermarket unit if you wish.

Additional Information on Diesel Injection Pump Failure

Here is another problem for first and second-generation PowerStrokes. The Bosch CP4 pump is what Ford was using, and they know it for having metal-to-metal contact in the pump. The challenge associated with this is that there are lost metal bits that race through the diesel fuel system.

This can eat up other components and affect some or all of the fuel system. It can get very costly, too.

If you have a third-generation PowerStroke, luckily, it uses a different pump.

If you notice any of the following, your diesel fuel system may be on the fritz:

  • Stalling
  • It takes longer to start the engine
  • Rough idle
  • Lack of power

While it seems to relate to the fuel flow only, sometimes the pump will flat-out fail. The worst part is that if the pump will die, it can run over $10,000 to repair.

Ford PowerStroke 6.7L Turbocharger Problems

This is another problem that is associated with an earlier generation. Specifically, the first-generation experiences failures occasionally related to turbo bearing. There is a lot of speculation that this is because Ford chose a turbo too small for the torque and boost requested.

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 it at no cost and no obligation to see if you have a case. We will either submit a claim to the manufacturer or file suit immediately.

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.

Contact us now or click here to learn more about PA Lemon Law, NY Lemon Law, or NJ Lemon Law, discover your options if you have Ford 6.7 diesel problems.

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