The 6.7 Powerstroke engine, introduced by Ford in 2011, has become one of the most popular diesel engines used in heavy-duty trucks. Known for its power, towing capacity, and fuel efficiency, the 6.7 Powerstroke has made a name for itself in the diesel truck market. However, not every model year of this engine is perfect. Some years of the 6.7 Powerstroke are riddled with problems that truck owners should be aware of before making a purchase. In this guide, we will dive deep into the problematic years of the 6.7 Powerstroke, why you should avoid them, and how to ensure you are getting a reliable truck when shopping for a used vehicle.
What Makes the 6.7 Powerstroke Popular?
The 6.7 Powerstroke is revered for its performance, efficiency, and dependability in the right conditions. As the first engine Ford designed and built in-house for their Super Duty trucks, it stands as a testament to Ford’s innovation and dedication to delivering powerful diesel engines.
Key Features of the 6.7 Powerstroke:
- High Towing Capacity: The 6.7 Powerstroke delivers impressive torque, making it a favorite for heavy towing jobs. With models producing over 440 horsepower and 860 lb-ft of torque in some years, this engine is known to handle even the most demanding towing tasks.
- Fuel Efficiency: Despite its power, the 6.7 Powerstroke is designed to maintain a respectable fuel economy for a heavy-duty diesel truck. The combination of a large turbocharger and direct fuel injection contributes to its better-than-expected miles per gallon (MPG) for this class.
- Durability: When properly maintained, the 6.7 Powerstroke is known to last well over 200,000 miles. Ford designed this engine to endure heavy use, making it popular among fleet owners, contractors, and recreational truck buyers alike.
However, despite its strengths, some model years have been plagued with issues that have led to significant repair costs for owners. Let’s explore which years of the 6.7 Powerstroke are best to avoid.
The Problematic Years of the 6.7 Powerstroke Engine
Although the 6.7 Powerstroke engine has generally earned a positive reputation, certain production years have experienced significant issues that have left owners frustrated and burdened with high repair costs. Below, we’ll break down the most troublesome years for this engine and the specific problems each year encountered.
2011-2012: Early Production Issues
The first iteration of the 6.7 Powerstroke, released in 2011, was highly anticipated. However, as with many new engine designs, it experienced several teething problems during its initial release.
Common Issues in 2011-2012 Models:
- Turbocharger Failures: One of the most notable issues with early 6.7 Powerstroke models was turbocharger failure. The ceramic ball bearings used in the turbo were prone to failure under heavy loads, especially when towing. This often resulted in poor engine performance and costly repairs.
- EGR Cooler Problems: Early models also faced issues with the Exhaust Gas Recirculation (EGR) cooler. When the EGR system failed, it led to overheating and, in some cases, cracked cylinder heads. This issue is particularly problematic because it can cause catastrophic engine failure if not addressed early.
- Fuel System Failures: The fuel system, particularly the high-pressure fuel pump, was another common area of concern in these early models. Contaminated fuel, especially water in the diesel, would cause the fuel pump to fail, which could then result in damage to the fuel injectors and even the engine.
For truck buyers considering a used 6.7 Powerstroke from 2011 or 2012, these issues make these years risky. Without proper repairs or upgrades, owning one of these models can quickly become a costly endeavor.
2017: Post-Facelift Problems
In 2017, Ford introduced a major facelift to the Super Duty lineup, which included a reworking of the 6.7 Powerstroke engine. While many improvements were made to boost performance and efficiency, new problems arose, particularly concerning the transmission.
Common Issues in 2017 Models:
- Transmission Failures: The 6-speed automatic transmission that was paired with the 6.7 Powerstroke in 2017 models experienced several reliability issues. Owners reported rough shifting, hesitation, and outright transmission failure, especially under heavy towing conditions.
- CP4 Fuel Pump Issues: Similar to the earlier models, the 2017 models also had recurring issues with the CP4 high-pressure fuel pump. The CP4 pump is highly sensitive to fuel quality, and any water contamination could lead to pump failure, requiring an expensive replacement of the entire fuel system.
- Injector Problems: Many owners of 2017 models also reported fuel injector failure. This would cause rough idling, loss of power, and increased emissions, which were exacerbated under heavy load or towing conditions.
For those considering a 2017 6.7 Powerstroke, it’s crucial to have the transmission and fuel system thoroughly inspected before purchase, as these repairs can cost thousands of dollars if not addressed early.
2020: New Emission Standards, New Problems
In 2020, stricter emissions standards were implemented, and as a result, Ford introduced several changes to the 6.7 Powerstroke to meet these requirements. While these changes improved emissions compliance, they introduced new problems for owners.
Common Issues in 2020 Models:
- Exhaust Gas Recirculation (EGR) Failures: The updated EGR system, which was necessary to meet emissions standards, proved to be unreliable. Many owners reported that the EGR valves would clog or fail, leading to reduced engine performance and increased emissions. This also triggered check engine lights and forced the vehicle into limp mode.
- Diesel Particulate Filter (DPF) Problems: The Diesel Particulate Filter, another emissions-related component, has caused significant headaches for 2020 6.7 Powerstroke owners. When the DPF fails, it results in decreased fuel efficiency, increased emissions, and costly repairs. The regeneration process for the DPF also causes issues, leading to excessive backpressure and engine overheating in some cases.
- Turbocharger Failures: While turbocharger technology has improved since the early years, some 2020 models still experienced turbocharger issues, particularly with excessive soot buildup in the exhaust system.
While the 2020 model introduced better fuel efficiency and lower emissions, these mechanical problems make it a model year to approach with caution, particularly for those who plan on heavy towing or long-term use.
Why These Years Should Be Avoided
The problematic years of the 6.7 Powerstroke engine – 2011-2012, 2017, and 2020 – share a common theme: costly repairs due to engine and transmission failures. But why exactly should these years be avoided?
Repair Costs
- Turbocharger Failures: A failed turbocharger can cost upwards of $3,000 to replace, not including labor.
- Fuel System Repairs: Replacing the high-pressure fuel pump, fuel injectors, and related components can easily reach $10,000, especially if the entire system is contaminated.
- Transmission Repairs: Transmission issues, particularly in the 2017 models, can cost anywhere from $3,000 to $5,000 for a rebuild or replacement.
- EGR and DPF Repairs: Repairing or replacing the EGR system and DPF can cost between $1,500 and $4,000, depending on the extent of the damage and whether replacement parts are needed.
Long-Term Reliability Concerns
Trucks with the 6.7 Powerstroke from these problematic years may have long-term reliability concerns. Owners who purchase these trucks without addressing the common issues may face frequent and expensive repairs, leading to downtime and frustration. Although some owners may experience fewer problems, the risk is high enough to warrant caution when considering a truck from these years.
How to Identify Problematic 6.7 Powerstroke Models Before Buying
If you’re in the market for a used truck with a 6.7 Powerstroke engine, especially from one of the years mentioned, it’s critical to conduct a thorough inspection before purchasing.
Key Inspection Points:
- Service History: Always ask for the truck’s full service history. Look for signs that the fuel system, turbocharger, and EGR components have been maintained or replaced. If major repairs have already been done, this can be a good sign that the truck has been properly cared for.
- Test Drive: Take the truck for a test drive and pay close attention to how it shifts gears. Rough shifting or hesitation could indicate transmission issues, particularly in 2017 models. Additionally, listen for any whining or whistling sounds from the turbocharger, which could indicate impending failure.
- Pre-Purchase Inspection: Have a certified mechanic who specializes in diesel engines inspect the truck before purchase. They can identify potential issues with the fuel system, transmission, and emissions equipment that may not be immediately obvious.
By taking these steps, you can avoid purchasing a truck that will lead to costly repairs down the line.
Alternatives to Avoiding 6.7 Powerstroke Issues
If you’re looking to avoid the common problems associated with the 6.7 Powerstroke engine but still want a reliable diesel truck, consider the following alternatives:
Buy Newer Models
Starting in 2021, Ford introduced updates to the 6.7 Power
stroke that resolved many of the issues seen in previous years. These models have improved fuel systems, more reliable turbochargers, and fewer emissions-related problems.
Consider Other Engines
If you’re still hesitant about the 6.7 Powerstroke, you may want to consider alternative diesel engines from other manufacturers, such as:
- Duramax (GM/Chevrolet): Known for its reliability and solid performance, the Duramax diesel engine is a popular choice for heavy-duty truck buyers.
- Cummins (Dodge/Ram): The Cummins diesel engine has a long-standing reputation for durability and power, making it a strong contender for those looking for a reliable diesel truck.
Frequently Asked Questions (FAQs)
What are the best years for the 6.7 Powerstroke?
The best years for the 6.7 Powerstroke are generally considered to be from 2013-2016 and 2021-present. These years saw improvements in reliability, fuel system upgrades, and fewer issues with the turbocharger and emissions equipment.
Are 2011 and 2012 6.7 Powerstroke models really that bad?
Yes, 2011 and 2012 models experienced significant problems, especially with the turbocharger, fuel system, and EGR cooler. Unless these issues have been addressed, they are not recommended for purchase.
What common signs indicate issues in a used 6.7 Powerstroke?
Look for signs of rough shifting, turbo whine, engine hesitation, check engine lights, and soot buildup in the exhaust. These can all indicate potential issues with the fuel system, turbocharger, or emissions components.
How expensive are repairs for problematic 6.7 Powerstroke engines?
Repair costs can range from $3,000 for turbocharger repairs to $10,000 or more for full fuel system replacements. Transmission repairs in 2017 models can also be costly, typically around $4,000.
Can the 6.7 Powerstroke be made more reliable with aftermarket upgrades?
Yes, many owners install aftermarket fuel pumps, turbochargers, and emissions delete kits to improve the reliability of their 6.7 Powerstroke. However, emissions delete kits may violate local emissions laws.
Conclusion: Is the 6.7 Powerstroke Worth the Investment?
The 6.7 Powerstroke is a powerful, fuel-efficient engine that has proven its worth in the heavy-duty truck market. However, certain model years, including 2011-2012, 2017, and 2020, have been plagued by costly reliability issues. For buyers considering a used 6.7 Powerstroke, it’s essential to conduct a thorough inspection and be aware of the potential pitfalls of these years. In most cases, it’s best to avoid these years altogether and opt for a more reliable model or consider other diesel engine options such as Duramax or Cummins.
Before buying, always consult with a certified mechanic, review the truck’s service history, and carefully assess whether the potential risks outweigh the benefits. By taking these steps, you can ensure that your investment in a 6.7 Powerstroke is a sound one.