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Most Common Ford 6.7L Power Stroke Engine Problems

Now nearly a decade old, Ford’s best diesel engine is far from “issue-free”

Oct 10, 2020
Continuing our informal "series" on diesel-engine problems—common, and, not-so-common—we're focusing our attention on the Ford 6.7L Power Stroke (code name "Scorpion"), an engine developed exclusively by Ford engineers and assembled completely in-house that's used in Super Duty rigs from 2011 to today.
The "six-seven" has proven itself to be a good engine in the near-decade it has been around. There are three generations of the powerplant: 2011-2014 (First), 2015-2019 (Second), and the Third-gen torque monster (1,050 lb-ft) found in 2020-2021 F-Series trucks. Through the years, we've found that first-gen Ford 6.7L diesels are the most problematic, but issues generally span through the entire run.
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Injection-Pump Fail
The injection pump is the Achilles heel for all 6.7L Power Stroke engines prior to 2020. The pump, a Bosch CP4.2, is known for breaking down due to metal-on-metal contact that is promoted by air inside the pump. The contamination can completely destroy the fuel system (injectors, pressure regulators, lines, etc.) and warrant very expensive repairs.
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Leaks, and Bad Bearings
Early versions of the oil burner can experience broken glow plugs—which can be catastrophic—and flaws in the primary stock radiator and at the coolant inlet on the turbocharger that cause leaks. Although glow-plug breakage can cause severe damage to the engine, ceramic ball-bearings in the turbo (2011-2012 engines) ultimately are the biggest concern, as their failure's commonality is akin to how regular 6.0L EGRs have problems.
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Not Cool
Surprisingly, the EGR coolers in 6.7L Power Stroke engines are also concerning. Although they don't just straight-up fail like 6.0L and 6.4L coolers are known for doing, the 6.7L units are prone to experiencing severe soot buildup (Diagnostic Trouble Code P0401 verifies this), ultimately to a point where replacing the entire cooler is required.
Photo 9/10   |   009 Most Common Ford 6 7l Power Stroke Engine Problems
NOx'd Out
There haven't been a lot of electrical issues with the 6.7L Power Stroke, but a problem with NOx sensors on first-gen engines (through 2013) is common and critical enough for us to include in this rundown. A sensor's failure causes the ECM to command "Limp Mode," which renders a truck severely underpowered.
Photo 10/10   |   010 Most Common Ford 6 7l Power Stroke Engine Problems

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