6.4 Powerstroke Problems
January 6, 2022

6.4 Powerstroke Problems

Written By: ProSource Diesel

The 6.4 Powerstroke engine was very short-lived in Ford trucks. It was the last diesel engine for Ford made by International. Its successor was the 6.7 Powerstroke, which was built by Ford in-house. When the 6.4 Powerstroke came out, it was considered an improvement over the 6.0 Powerstroke.

However, it was eventually found to have its own array of problems. Some of these problems can be quite costly, but others can be fixed fairly easily by replacing factory parts with higher-quality aftermarket diesel parts.

ProSource Diesel takes a look at some of the most common problems with the 6.4 Powerstroke, what causes them, and what can fix them.

Oil Dilution

This is a very common problem in 6.4 Powerstroke engines. If you’ve ever changed the oil on a 6.4 Powerstroke, you might have wondered about all the extra oil coming out. Owners of the 6.4 have reported several quarts and even up to a gallon of extra oil that shouldn’t be there.

The truth is that it’s not actually oil. In fact, it’s diesel fuel. The 6.4 includes an emissions process that leads to oil dilution. The problem is that fuel in your oil reduces the lubrication of oil to your engine’s essential parts.

How do you fix oil dilution? The first step is to check and change your oil frequently. By checking it frequently, you can find out if your oil capacity is too high. Always use high-quality oil that meets or exceeds OEM standards and quality Powerstroke parts like Motorcraft filters.

Shop for: Powerstroke 6.4 lubrication system parts

Leaky Radiator

If you see a puddle of coolant underneath your 6.4 truck, it’s probably not a blown head gasket. This engine is notorious for developing a leaky radiator. This is mainly due to the poor radiator design from the factory.

The solution to this common problem is to replace the factory radiator with better quality 6.4 Powerstroke aftermarket parts like an aluminum 6.4-liter Powerstroke radiator.

Shop for: Powerstroke 6.4 cooling system parts

Bad Fuel Economy

Even though the 6.4-liter was developed with a major increase in power over the previous engine, it lacked decent fuel economy. The main culprit here is the diesel particulate filter.

As a part of new emissions standards, the DPF substantially reduced emissions, but it also reduced fuel economy, and especially in city driving. There are a few 6.4 Powerstroke performance parts that can help you regain fuel economy.

These include aftermarket parts like a cold air intake, a new intercooler, and a tuner that won’t delete your emissions devices. At ProSource Diesel you can find diesel truck parts like these and much more to get the most out of your 6.4 Powerstroke.

Shop for: 6.4 fuel system parts

Other DPF Problems

The DPF on the 6.4 Powerstroke was designed to reduce tailpipe emissions, which it definitely did. It was the first emissions system of this type to be installed on a Powerstroke engine. However, it was eventually found to cause other issues apart from reducing emissions, including the following:

  • Clogging
  • Leaking
  • Sensor failure

Fixing DPF problems can be difficult and expensive. It often requires the replacement of various diesel parts, including the DPF system itself. The good news is that you can get aftermarket DPF systems that work much better than factory Ford Powerstroke parts.

Shop for: Powerstroke 6.4 sensors

Cracked Up-Pipes

Have you noticed a lot of soot in the engine compartment of your 6.4-liter Powerstroke? If you see excess soot on your firewall or hood, it might be from cracked turbo up-pipes. You might also hear a hissing noise under the hood with the engine running.

This is a common problem and can result in a huge loss of power. The only option for dealing with cracked up-pipes is a replacement. However, like the previous items, don’t replace them with factory parts.

Quality aftermarket parts provide superior design and construction, plus they often come with lifetime warranties.

Shop for: Powerstroke 6.4 up pipes

Clogged EGR Coolers

The 6.4-liter Powerstroke has two EGR coolers to reduce the temperature of hot gases from the exhaust. Coolant is used to do this, which means that it will also break down over time and eventually clog the coolers.

The main headache here is that the 6.4 uses two coolers, so you have potentially two clogged coolers to figure out. The solution is to invest in a coolant filtration system to increase breakdown time and keep your coolers from clogging as often.

Shop for: Powerstroke 6.4 EGR coolers

Piston Failure

The factory pistons on the 6.4-liter Powerstroke are simply not very durable. Cracks often develop on the fuel bowl and then lengthen to damage the entire piston.

If the crack is bad enough and you don’t catch it, the piston can start to disintegrate and may cause catastrophic engine damage. Some symptoms that indicate piston failure include the following:

  • Excessive white smoke
  • Compression loss
  • Loss of power
  • Misfires

Like the DPF system, replacing 6.4 Powerstroke pistons is a labor-intensive and expensive job. Generally speaking, it’s a good idea to replace all 6.4 pistons and any other worn parts while you’re in there. One cracked piston is not likely to be worth the cost or labor.

Shop for: Powerstroke 6.4 Powerstroke engine parts

Count on ProSource Diesel for performance and aftermarket 6.4 Powerstroke parts to repair common problems with this engine. Aftermarket Ford Powerstroke parts often meet or exceed OEM standards, and we carry the widest selection. That’s why we are where diesel repair shops shop for diesel parts.

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