The 6.4 Powerstroke engine from Ford was a successor to a 6.0L engine. It was produced between 2008 and 2010, and it did produce an impressive 350 hp and 650 torque. It was considered an improvement to a 6.0L which proved to be problematic. But, time showed that 6.4L also has its share of problems. But is there a way how to fix 6.4 Powerstroke problems without the need to break the bank?
One of the most common problems of this engine is a leaky radiator. The only fix for this stock engine problem is to use an aftermarket radiator option. Problems with cracked stocked pistons have the same fix – finding an aftermarket option. The mix of fuel and oil is also common. The only way to fix this is to frequently change the oil and the filter – best at every 4,000 miles.
This engine has several other issues, like cracked-up pipes, high tailpipe emissions, and bad fuel economy. We will address these problems and all the others we can think of. But not only that, but we will offer some way to at least make these problems easier to handle. Enjoy!
Common 6.4L Powerstroke Problems
Powerstroke is a diesel engine family that produced some great engines, like the 7.3L used as a workhorse engine. But, there are some complete misses, like the 6.0L engine, which is plagued with numerous problems.
Its successor, the 6.4L engine, introduced additional emission control components that brought some new problems. Unlike the 6.0L engine, the 6.4L can be managed to be a real powerhouse, but it demands a major overhaul.
Poor fuel economy may be one of the top problems that are hard to resolve. The new DPF is always thirsty for more fuel, and that is the main reason for the low MPG score.
Leaking Radiator
Poor radiator design and materials used for making it are the main issues that cause this common problem. While most engines have aluminum radiators, this 6.4L has a plastic one. We don’t even want to mention cheap bonding between the core and the tank. The vibrations of the engine are enough to create numerous cracks resulting in a puddle of coolant under the truck.
Problems with the radiator often lead to engine overheating and catastrophic engine damage. The radiator usually lasts around 100,000 miles. But, if the engine frequently overheats, that will speed up the development of this problem.
Overheating of the engine is one of the most serious issues that an engine can go through. A radiator that doesn’t do its work can lead to warping of the pistons and valves. Once you let them fry, you will need to rebuild the whole engine block.
How To Fix A Leaky Radiator?
The best and the only way to fix this properly is to get an aluminum-made aftermarket radiator. You can install some kind of support brace, but it will not solve the problem in the long run.
Bad Fuel Efficiency
The new diesel particulate filter (DPF) emission control system is the main culprit for the bad fuel economy. Yes, this engine is not one of the high-mileage engines, but the DPF is only making it worse. When the truck is driven at low speed or in a city traffic jam, the DPF needs more fuel. The more you drive the truck at low speed, the more you will need to regenerate the DPF.
How To Fix?
Everything you do will only make small improvements. For a start, you can add the aftermarket lift pump. Next, you can improve the intake airflow with better aftermarket cold air systems. You can even think about adding an air-to-air intercooler to help cool the turbocharger. There are also options for ECM tuning and engine calibration that will somewhat lower fuel consumption.
Fuel in Oil
Mixing oil with diesel fuel is another problem pinned on the DPF. The DPF is kept clean with the active regeneration process. This engine does this by injecting fuel during the exhaust stroke. This way, the fuel exits the cylinder and flows downstream to the exhaust. This burns off the soot from the DPF.
Most engines use a dedicated fuel injector to spray the fuel directly into the exhaust stream. In theory, this sounds good. But, in this engine, the injectors spray the fuel on the cylinders on the exhaust stroke. This creates a build-up of fuel deposits on the cylinder walls, which can contaminate the oil.
If too much fuel mixes with the oil, it will contaminate the oil. It will not be able to lubricate and cool the moving parts of the engine properly. This will shorten the work life of the entire engine.
How To Fix?
There is no sure fix for this problem. You can shorten the oil change interval to prevent oil from becoming too dirty. You can try to idle as little as possible. That is when the cylinders cool down. Then, the fuel sticks to the walls of the cylinders and mixes with oil. Also, if you use the truck for heavy towing, warm it before that. Another good thing is to avoid using poor fuel quality.
Fuel & Water Separator Problems
The fuel and water separator often clog if it is not drained frequently enough. When water and fuel mix, they coagulate and create a sludge. That sludge will eventually clog the drain valve. If the water level continues to increase, it will enter the fuel system. Water in the fuel system will end up with rust and poor fuel quality.
The high-pressure fuel system is prone to problems and malfunctions when using low-quality fuel. This engine uses the K16 pump which is easily corrupted by rust and low fuel quality. If the pump is exposed to it for a longer period, it can self-destruct. If that happens, the metal shrapnel and particles will enter the injectors causing massive damage to the entire fuel system.
How To Fix?
It is highly recommended to drain the fuel and water separator every time you change the oil. If that is not enough, drain it every couple of weeks. You can also install a fuel lift pump. It offers better filtration features and decent fuel economy, and the whole fuel system will work longer.
Bad Pistons
This problem is not that common but can cause serious damage. This happens when the engine has already passed the 200,000-mile mark. Tuned engines are also more susceptible to problems with pistons.
Factory pistons are not entirely bad; they are just not that durable. The main problem is in the fuel bowl. The piston cracking starts there. From there, the cracks can go through the entire piston. We don’t need to mention that it will cause problems for crucial engine components.
What are the Symptoms of Piston Failure on 6.4 Powerstroke?
This list of symptoms can be used for different problems, but in this engine, cracked pistons are to blame:
- Lots of white smoke coming out of the tailpipe
- Engine stalling and misfires
- Loss of power
- Loss of compression
How To Fix?
This will demand an engine rebuild that will cost a lot to repair. Using upgraded pistons is the best option. Labor costs will be serious because this job is difficult and takes time. If you want to upgrade something in the engine, use this opportunity.
Check Out COMMON Ford POWERSTROKE 6.4 Issues and PROBLEMS:
Torn Exhaust Pipes
The exhaust pipes connect the exhaust manifold with the turbocharger. They pass the exhaust gasses to the turbo, where they provide a boost. Vibrations and heat cycles cause serious problems for expansion joints on the pipes. They often crack and create an exhaust leak. The exhaust leak will cause a serious diesel soot build-up. The turbo function will also go bad. It will produce less power and will be under serious stress.
What are the Symptoms of Torn Exhaust Pipes on 6.4 Powerstroke?
Fortunately, some clear symptoms will point to a problem with exhaust pipes:
- Power loss when accelerating
- Slow turbo spool. The turbo will need more time to build up pressure
- Engine bay full of soot
- A hissing sound came from the engine compartment.
How To Fix?
Like with most of these fixes, installing an aftermarket exhaust pipe is the best way. That way, you will resolve this issue for a long time. The factory Up-pipes will lead to the same problems after some time.
Front Cover Leaks
The usual suspect for front cover leaks is cavitation—low coolant levels cause cavitation behind the water pump. Very quickly, it will eat through the front cover. When that happens, the engine coolant starts leaking into the crankcase. The coolant will destroy the bearings and other engine components very fast. Pushrods and valve trains are the first to be damaged by the coolant.
How To Fix?
Get a coolant filtration device and replace the front cover. It is recommended to use high-quality cooling fluid and good additives for it. Before you buy those, check the manufacturer’s recommendations.
Clogged EGR Coolers
This engine has two EGR coolers. The lower one, which is located on the left side of the exhaust manifold, is the problem. It tends to get clogged, leading to engine overheating, restricted coolant flow, and leaking. That can lead to coolant loss and overheating, which can result in serious engine damage.
If the cooler is leaking while the engine is not running, the cooler can enter the cylinders through the exhaust valves. If you try to start the engine after that, that can lead to hydro locking. The coolant in the cylinders doesn’t allow the engine to start. The connecting rods may bend, resulting in serious damage.
What are the Symptoms of Bad EGR on 6.4 Powerstroke?
These issues are the most probable reasons that will point to a faulty EGR:
- Check engine light comes on
- Stalling and rough idle
- Even worse fuel economy
- Strange sounds coming from the engine.
How To Fix?
The best thing to do is to buy a coolant filtration system. It will prolong breakdown time, and the coolers won’t be clogged that often. Also, look for aftermarket coolers that will do a better job.
People often think about removing the EGR, but beware that your truck will not comply with the emissions standards. Emissions laws are strict, and you cannot pass emission tests.
High-Pressure Fuel Pump Wire
The first models with this engine are prone to chafing of the fuel pump wire. That happens because of extensive vibrations with passing time that will leave the wires exposed. When that happens, that can cause a short circuit of the high-pressure fuel pump.
How To Fix?
Ford noticed this problem and added a protective covering for the wire harness in later models. Newer Ford models have them factory installed, but you can buy them and install them at older models too.
Clogged Engine Oil Cooler
A clogged engine oil cooler is often overlooked, and the clogged EGR cooler takes the blame instead. When it gets clogged it blocks the passage of the oil cooler. The oil cooler cools down the engine oil with a coolant. When there are clogging issues, the engine oil temperatures will rise.
How To Fix?
The easiest way is to check the temperature of both the oil and the oil coolant. If the difference between oil and coolant temperature is more than 14 degrees, then the coolant is in trouble. Once the oil cooler gets clogged, it cannot be cleaned.
The only way to fix this problem is by replacing the part. Stock engine oil coolers can last between 50,000 and 75,000 miles. If you choose an aftermarket option, it will last longer and do its job better.
FAQs
How long will a 6.4 Power Stroke engine last
One of the biggest 6.4 Power Stroke V-8 diesel engine problems is its reliability. Or the lack of it. Its work life is between 150,000 and 200,000 miles. But, sometimes, you don’t see it coming. It can act as a time bomb. But, if you change the problematic stock parts with aftermarket ones, you will extend your work life.
Ford is using and has used other, more reliable engines. Cummins 5.9L engine is one of the engines that comes to mind when thinking about larger Ford trucks.
Who manufactures the best 6.4 Powerstroke engine?
One manufacturer stands out from the rest: the DFC Diesel Rebuilders. Their engines come with a 5-year and 100,000-miles warranty. They make engines for different purposes like towing and regular daily driving.
How much does tuning a 6.4 Powerstroke cost?
For this operation, you will need several components:
– A performance monitor. An Edge Insight CTS3 will do a great job. It costs between $450 and $500
– A quality tuner. A great and affordable tuner that is compatible with this engine comes from Banks. For around $650, you get a tool packed with great and modern tuning features
– A new engine coolant filtration system. Just the one from Mishimoto for around $200 will do the job nicely
– Replacement for a stock radiator and upper support bar for it. A radiator from Mishimoto costs around $1,500, while a bar of the same brand costs $400
– Cold Air intake system. Banks have proven themselves in this market, and their air intake system is worth the price of $450
– Replacement for the low-quality factory up-pipes. A heavy-duty pipe-up setup from Rudy for $270 is a great pick
– A new EGR cooler kit. A great substitute comes from Bullet Proof Diesel for around $1,000
– A new aftermarket engine oil cooler. Again, Mishimoto does this great, and their option for $140 is a great choice.
So, if you want to make this engine work properly, you will have to invest around $5,000.
Final Considerations
Yes, the 6.4L Powerstroke has numerous issues like its predecessor, 6.0L. The biggest one is that those issues will shorten its work life tremendously. With 200,000 miles on the clock, you already need to think about the capabilities of this engine to work regularly.
Thankfully, if you love its massive power and torque output and have extra money, you can make a great engine. You will have a good and powerful engine with aftermarket parts, like up-pipes, oil and EGR cooler, a new intake system, and a radiator. It all depends on whether it is worth it for you.
