A lot of new attention has been focused on Ford’s 6.7-liter Power Stroke diesel engine with the announcement of the new High Output version. The 6.7-liter has weathered over a decade in three generations of Super Duty Ford trucks. It has been a dependable, workhorse of a powerhouse that was engineered and produced exclusively by Ford. Now, with the 2023 6.7 HO cranking out 1,200 lb-ft of torque, buyers want to know how good, or bad, Ford’s six-seven has been.

Nothing is perfect, and there are issues that have cropped up over the diesel’s long lifespan. Some affect only certain generations, while others plague all of the six-seven generations. We’ll look at the major problems that crop up in forums and treatises. 

What are the three generations of the 6.7 Power Stroke engine?

power stroke

1999 Ford F-350 Power Stroke | Ford

The three generations of the six-seven are 2011 to 2014, 2015 to 2019, and 2020 to 2023 Super Duty F-Series trucks. According to our pal KJ at MotorTrend, the first generation is the one that generally has the most issues. But some of those problems have carried through to all years of the Powerstroke. 

The known problems with the first-generation diesel resulted in a revised 2015 second-gen. Torque and horsepower were increased, but reliability issues were also addressed. The same can be said for the current generation of 6.7 liters. Following are the most common problems that beset the six-seven.

Turbocharger Problems

The first-gen 6.7 used a rather unique design for its turbocharger. It was actually more like a compound turbo system with two of them in tandem. Once exhaust gasses are passed through the first turbo, the compressed exhaust goes through two smaller units to further increase its compression. 

So there is much more air volume running through the turbo. Early versions used ceramic bearings for the wheels, which failed often. Steel bearings soon replaced them with much better results. Aftermarket upgrade kits are a smart purchase to get more longevity out of this more complicated turbo setup.

6.7 Exhaust sensor failures

power stroke

2000 Ford F-250 Power Stroke | Ford

There are four exhaust sensors. Unfortunately, when a sensor fails it puts the truck into limp mode. The code that is flashed will identify which of the four has failed, making diagnosis easy. And replacing them is a fairly simple process.

Turbo coolant leaks

Some posters have described coolant that puddles on top of the engine. This is caused by a leaking turbo coolant line fitting. Unfortunately, accessing it requires the removal of the upper intake manifold. But replacing the fitting and coolant line most often fixes the leak.

6.7 EGR system clogs

Though fairly robust, the main problem with the EGR system is clogging. Soot gets packed into them which will trigger a code. Though fairly easy to replace, you may need to explore the system for other less common issues. Or, you can just replace the cooler and hope the system functions like normal.

Glow plug failure

power stroke

2000 Ford F-250 Power Stroke | Ford

This was a recurring problem with the first-year 6.7-liter. When the glow plugs fail, they can break apart causing catastrophic engine damage. Your best bet is to determine if the glow plugs have been updated, or replace them if you’re not sure. Replacement glow plugs run between $30 and $60 each.

Fuel pump/fuel system problems

The 6.7 Power Stroke fuel system will normally not give the owner problems. That is unless the injection pump fails. If this happens, debris will run through the entire fuel system, meaning not only the injection pump but the injectors and pressure regulators must all be replaced. Also, the entire system will first need to be cleaned up. 

One tip is to regularly replace the filters to avoid particles impacting the fuel pump. Using a better diesel blend is also recommended, rather than that old cheap stuff.

TECH NEWS RELATED

3 Most Reliable Lexus Models

While there are a few automotive brands out there known for being reliable, one of the top companies with several durable models in its lineup is Lexus. Which vehicles are the top three for being reliable rides? Why does reliability matter? Lexus logo | Getty Images When you buy a ...

View more: 3 Most Reliable Lexus Models

The Cheapest New Dodge Charger Is a Versatile Sedan Option With One Big Issue

The Dodge Charger offers everything from a sensible V6 and all-wheel drive to supercharged tail-happy sports sedans. Better yet, the cheapest offering in the model’s lineup, the SXT, is versatile and well-suited for daily driving. However, the 2023 Dodge Charger SXT has one glaring issue: it’ll be the last car ...

View more: The Cheapest New Dodge Charger Is a Versatile Sedan Option With One Big Issue

Cheapest New Audi Is 1 of the Best Small Luxury Cars, Says Car and Driver

Audi has a solid lineup of luxury vehicles — with their good driving dynamics, premium features, and attractive designs. Also, compared to some other luxury brands, Audi models are relatively affordable. This includes the 2023 Audi A3 subcompact sports sedan, which is the cheapest new Audi car. Also, according to ...

View more: Cheapest New Audi Is 1 of the Best Small Luxury Cars, Says Car and Driver

GM Just Announced An All-New Small-Block V8 Is Coming

The electrification zeitgeist is in full swing, but gasoline-powered engines won’t disappear overnight. Nor will V8 power, as GM just confirmed a new small-block V8 engine is coming soon. This will be the sixth generation of the legendary small-block V8 that has powered so many Chevy and GM products since ...

View more: GM Just Announced An All-New Small-Block V8 Is Coming

Best car tool kits 2023

Whether you're looking for an emergency set of basic tools or something more comprehensive, a good tool kit can save you lots of stress – but who makes the best?...

View more: Best car tool kits 2023

The Lectron Adapter Will Let You Charge a Ford Lighting at a Tesla Station

Electric vehicle charging ports are mess. Some use one type developed in Europe, others use a Japanese system, and then Teslas use their own. But, what about those who have access to a Tesla charger, but want to charge something else, like a Ford F-150 Lightning? The Ford F-150 Lightning ...

View more: The Lectron Adapter Will Let You Charge a Ford Lighting at a Tesla Station

How Much Does a Nissan Tune-up Cost, and What Do They Do?

Keeping up with your Nissan‘s regular maintenance means you get optimal performance and fewer chances of major breakdowns. With that, you save on fuel costs and significant repairs and avoid the inconvenience of your car breaking down or stalling in the middle of the road. Naturally, tune-ups are a considerable ...

View more: How Much Does a Nissan Tune-up Cost, and What Do They Do?

How Does the New Corvette E-Ray Stack Up Against Hybrid Hypercars?

The new 2024 Chevrolet Corvette E-Ray isn’t just the latest stage in the Corvette’s evolution into a world-class supercar. Instead, it’s a reminder that the latest generation of plastic fantastic can punch well above its weight class. For instance, the new hybrid Corvette is quick enough to compete with several ...

View more: How Does the New Corvette E-Ray Stack Up Against Hybrid Hypercars?

4 Snow Plow Safety Tips When Encountering These Vehicles on the Road

Alpine is Coming to the U.S, but it’s Not Bringing the Goods

What’s the Toyota Highlander Hybrid Towing Capacity?

1990s GMC Typhoon: There’s Never Been an SUV That Can Beat It

Your 2022 Ford Maverick Might Have Faulty Airbags

This Older Porsche Infotainment Upgrade Helps Modernize Your 911 and Cayenne

Only 1 Type of Buyer Should Even Consider the 2022 Jeep Compass

3 Most Common GMC Sierra 1500 Problems Reported by Hundreds of Real Owners

5 Used Cars with the Biggest Price Drops

Incredibly Rare and Awesome Pontiac GTO Judge Sold for $1.5 Million

Is the 2023 Toyota RAV4 Too Old to Keep Up?

Carroll Shelby’s 100th Birthday Honored by Centennial Edition Mustang

OTHER TECH NEWS

Top Car News Car News