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Understanding common issues with the 6.4 Powerstroke

Updated: Feb 5, 2023

The 6.4 Powerstroke engine is a diesel engine that was produced by Ford for use in their Super Duty trucks. It was introduced in the 2008 model year and was in production until 2010. While the 6.4 Powerstroke engine was generally well-regarded for its power and performance, it has had a number of reported issues over the years. Here are some of the most common problems that have been reported by owners:

  1. EGR cooler failure: The EGR (Exhaust Gas Recirculation) cooler is a device that helps to reduce emissions by recirculating some of the exhaust gas back into the engine. On the 6.4 Powerstroke engine there are two EGR coolers, and both of the EGR coolers have been known to fail, leading to a number of problems including reduced engine performance and the possibility of engine overheating due to coolant consumption.

  2. High-pressure fuel pump failure: The high-pressure fuel pump is responsible for supplying fuel to the injectors in the engine. On the 6.4 Powerstroke engine, the high-pressure fuel pump can fail internally, causing metal to flow through the entire fuel system resulting in the entire fuel system needing to be replaced.

  3. Injector failure: The injectors on the 6.4 Powerstroke engine have also been known to fail due to contamination, leading to reduced engine performance, no start conditions, or even the possibility of engine damage.

  4. Head gasket failure: The head gasket is a seal that sits between the cylinder head and the engine block. On the 6.4 Powerstroke engine, the head gasket can fail for many reasons. Symptoms of a failed head gasket include: white smoke out of the exhaust, poor drivability, no start condition, or in extreme cases, engine damage.

  5. Turbocharger failure: The 6.4 Powerstroke engine uses a variable geometry turbocharger (VGT), which is more complex and prone to failure than a standard turbocharger. A failed turbocharger can cause a loss of power, poor fuel economy, and in extreme cases- engine failure.

While these are some of the most common issues that have been reported with the 6.4 Powerstroke engine, it's important to note that not all owners have experienced these problems. If you own a vehicle with a 6.4 Powerstroke engine, it's a good idea to stay up to date on regular maintenance and to address any issues that may arise as soon as possible to help prevent further damage to the engine.

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