5 Common Issues With the Ford 6.4L Power Stroke Diesel

Problematic Powerplant

Though it's a popular entity these days, the Power Stroke diesel has had its fair share of well-documented issues over its years in existence, with each iteration having its own unique quirks. That includes the 6.4L Power Stroke, which debuted in the 2008 Ford Super Duty line of pickups, though it only hung around until 2010 when it was replaced by the modern 6.7L Power Stroke. Here, we've outlined five common issues that owners of 6.4L Power Stroke-powered pickups should be aware of. 

Photos: Ford

Oil Dilution

First up, we have oil dilution, which is the phenomenon that occurs when diesel fuel mixes with the engine oil during the active regeneration process. The 6.4 injects fuel into the exhaust stream to help combustion during the regen process, but oftentimes, it doesn't all get used up, and winds up contaminating the oil - which ultimately leads to more wear and tear on internal components, and ultimately, engine failure. This means owners should keep a close eye on oil levels, and use high-quality oil when changing it, too. 

Photos: Ford

Radiator Leaks

Radiator leaks are also quite common with the 6.4L Power Stroke diesel, largely due to a poorly designed radiator itself. Luckily, this particular problem is easy to spot, as faulty radiators tend to leave puddles of coolant behind, but as most are well aware, ignoring a major coolant loss is a great way to ruin an engine, too. 

Photos: Ford

Cracked Pistons

The pistons used in the 6.4L Power Stroke are another weak spot, as cracks tend to develop in those critical pieces over time. If left unchecked, this can lead to engine failure as well, meaning that one will want to listen out for things like knocking, excessive smoke, and higher oil consumption before it's too late. 

Photos: Ford

EGR System Failure

The exhaust gas recirculation system (EGR) used in the 6.4L Power Stroke is a big problem spot that frequently causes issues, particularly in engines with 100k or more miles. The EGR's pipe and valve can get clogged up with soot or be impacted by leaks as well, which can ultimately cause it to fail prematurely. Aside from keeping the system's pair of coolers clean, replacing them with beefier aftermarket units is a great way to prevent this from happening. 

Photos: Ford

Poor Fuel Economy

Many 6.4L Power Stroke owners experience poor fuel economy from their engines, which can often be traced back to the diesel particulate filter (DPF). During the active regeneration process, the DPF tends to consume more fuel, which means that when driving in heavy traffic, fuel economy can suffer in a notable way. Many choose to delete the DPF for this very reason, but a tune can also help without running into issues with the legality of that action. 

Photos: Ford

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