← Reference
For the used-truck buyer
6.0 vs 6.4 vs 6.7 Power Stroke, compared
Three generations of the Super Duty diesel: two built by Navistar for Ford, then Ford's own 6.7. Each one fails in its own way. What fails, what was recalled, what the repairs cost, with sources and no verdicts.
At a glance
The identity rows are facts from our platform records; the counts are what this site documents for each engine today.
| 6.0 Power Stroke | 6.4 Power Stroke | 6.7 Power Stroke | |
|---|---|---|---|
| Years | 2003.5-2007 Super Duty; Excursion to 2005, E-Series vans to 2010 | 2008-2010 Super Duty | 2011-present Super Duty (our records run through MY2026) |
| Built by | International / Navistar, for Ford | International / Navistar (MaxxForce 7 base), for Ford | Ford in-house, developed with AVL |
| Power / torque | 325 hp / 570 lb-ft | 350 hp / 650 lb-ft | 390 hp / 735 lb-ft at launch, 475 / 1,050 from 2020; High Output 500 / 1,200 from 2023 (pickups) |
| Fuel injection | HEUI: injectors fired by high-pressure oil (high-pressure oil pump, IPR valve, ICP sensor), driven by the FICM | Piezo common rail, Siemens K16 high-pressure pump | Bosch CP4.2 high-pressure pump, piezo injectors |
| Turbo | Variable-geometry turbo | Compound sequential VGT (low- and high-pressure turbos) | Garrett GT32 on ceramic bearings (2011-2014), GT37 journal-bearing from 2015 |
| Emissions hardware | EGR valve and EGR cooler; no DPF | EGR (dual coolers) and the first factory DPF; ultra-low-sulfur diesel only | EGR, DPF and SCR with DEF |
| What changes inside the range | Cylinder head dowel 18 mm to 20 mm at the 2006-01-16 build date: the head gasket part differs | One hardware spec across the run | Three hardware generations: 2011-2014, 2015-2019, 2020+ (steel pistons, 10-speed TorqShift) |
| Documented failure modes | 12 (10 verified) | 9 (6 verified) | 11 (10 verified) |
| NHTSA safety recalls naming the engine | 3 | 2 | 11 |
| Bulletins, programs and coverages | 33 | 5 | 3 |
| Repair recipes | 6 | 3 | 5 |
| Buyer's checklist | 6.0 Power Stroke checklist | 6.4 Power Stroke checklist | 6.7 Power Stroke checklist |
Power and torque are pickup ratings; chassis cabs run lower calibrations. The 6.4 and the 6.0 share four torque-to-yield head bolts per cylinder, which is why both carry head-stud stories. Recall counts follow the years each engine was sold: a longer run collects more campaigns.
What fails, engine by engine
Most widespread first. Each failure links to its full record (symptoms, cause, diagnosis, fixes, sources). Complaint counts are NHTSA owner complaints matched to that failure by keyword (unadjudicated) and only compare failures on the same engine, not engines with each other. How we tier facts.
6.0 Power Stroke
12 documented failure modes
- EGR cooler failure verified
- Engine oil cooler clogging / failure verified
- Cooling system degradation / no coolant filtration aggregated
- Marginal regulated fuel pressure (blue spring) contested
- FICM (Fuel Injection Control Module) failure verified Repair budget: about $150-$300 in parts (recipe)
- Head gasket failure / cylinder head lift verified
- STC fitting (high-pressure oil rail) failure verified
- Fuel injector stiction / failure verified Repair budget: about $85-$300 in parts (recipe)
- VGT turbocharger sticking verified
- IPR (Injection Pressure Regulator) valve failure verified
- Degas bottle / coolant reservoir crack, or failed cap verified
- Water pump failure verified
6.4 Power Stroke
9 documented failure modes
- High-pressure pump (Siemens K16) destruction verified Repair budget: about $2,100-$2,400 in parts, plus parts we have no price for (recipe)
- Compound turbo bearing-seal leaks verified
- Piston ring failure #7/#8 (regen fuel wash) verified
- DPF clogging / regeneration problems verified Repair budget: about $1,400-$2,650 in parts (recipe)
- EGR cooler failure -> #8 hydrolock verified Repair budget: about $1,400-$2,650 in parts (recipe)
- Rocker arm tip wear aggregated
- Front-cover pump cavitation erosion (coolant into oil) verified
- Head cracking under advanced-timing tunes aggregated
- Valve guide wear (no bronze sleeves) aggregated
6.7 Power Stroke
11 documented failure modes
- DEF / SCR / NOx sensor faults verified Repair budget: about $110-$4,400 in parts (recipe)
- CP4.2 high-pressure fuel pump contamination cascade verified Repair budget: about $2,100-$7,600 in parts (recipe)
- Low-pressure fuel supply weakness (lift pump, filters, water-in-fuel) verified Repair budget: $300.00 in parts at Dave's Auto Center (recipe)
- DPF clogging / regeneration problems verified Repair budget: about $110-$4,400 in parts (recipe)
- Piezo injector wear and fuel dilution of engine oil verified
- Dual-circuit cooling system leaks (radiator / crossover tube / degas bottle / water pump) verified
- EGR cooler thermal-fatigue coolant leak verified Repair budget: about $270-$910 in parts (recipe)
- EGR valve soot clogging / sticking verified Repair budget: about $270-$910 in parts (recipe)
- Intercooler condensation ingestion + cold-side charge-pipe fatigue aggregated
- Glow plug wear and cold-start faults, plus an isolated 2011-2013 tip-separation defect verified
- VGT turbocharger failure - generation dependent (ceramic-bearing GT32 vs journal-bearing GT37+) verified Repair budget: about $1,850-$2,000 in parts (recipe)
Same symptom, each engine
How many documented failures show each sign on each engine, and the most widespread one. Open a cell for every cause on that engine, ranked, with how to tell them apart.
| Symptom | 6.0 Power Stroke | 6.4 Power Stroke | 6.7 Power Stroke |
|---|---|---|---|
| Hard start / no-start | 5 causes FICM (Fuel Injection Control Module) failure | 2 causes High-pressure pump (Siemens K16) destruction | 4 causes CP4.2 high-pressure fuel pump contamination cascade |
| Stalls while driving | 3 causes FICM (Fuel Injection Control Module) failure | None documented | 1 cause CP4.2 high-pressure fuel pump contamination cascade |
| Power loss / limp mode | 3 causes Marginal regulated fuel pressure (blue spring) | 2 causes Piston ring failure #7/#8 (regen fuel wash) | 5 causes DEF / SCR / NOx sensor faults |
| White smoke | 3 causes EGR cooler failure | 1 cause EGR cooler failure -> #8 hydrolock | 3 causes Piezo injector wear and fuel dilution of engine oil |
| Blue smoke | None documented | 2 causes Piston ring failure #7/#8 (regen fuel wash) | 1 cause VGT turbocharger failure - generation dependent (ceramic-bearing GT32 vs journal-bearing GT37+) |
| Coolant loss | 5 causes EGR cooler failure | 3 causes EGR cooler failure -> #8 hydrolock | 2 causes Dual-circuit cooling system leaks (radiator / crossover tube / degas bottle / water pump) |
| Overheating | 6 causes EGR cooler failure | 2 causes Front-cover pump cavitation erosion (coolant into oil) | 1 cause Dual-circuit cooling system leaks (radiator / crossover tube / degas bottle / water pump) |
| Oil leak / consumption | 1 cause Engine oil cooler clogging / failure | 4 causes Compound turbo bearing-seal leaks | 2 causes Piezo injector wear and fuel dilution of engine oil |
| Engine noise | 3 causes FICM (Fuel Injection Control Module) failure | 2 causes Compound turbo bearing-seal leaks | 3 causes Dual-circuit cooling system leaks (radiator / crossover tube / degas bottle / water pump) |
| Misfire / rough running | 8 causes EGR cooler failure | 2 causes Piston ring failure #7/#8 (regen fuel wash) | 5 causes Low-pressure fuel supply weakness (lift pump, filters, water-in-fuel) |
| DEF / DPF warnings | None documented | 1 cause DPF clogging / regeneration problems | 2 causes DEF / SCR / NOx sensor faults |
| Metal in filter / oil | None documented | 1 cause High-pressure pump (Siemens K16) destruction | 1 cause CP4.2 high-pressure fuel pump contamination cascade |
Trouble codes our records tie to failures on more than one of these engines: P0299 (underboost) on 6.0 Power Stroke and 6.7 Power Stroke; P2463 (DPF soot accumulation excessive) on 6.4 Power Stroke and 6.7 Power Stroke.
Safety recalls
NHTSA safety recalls whose text names the engine, newest first, with NHTSA's own risk statement. Bulletins and programs are on each engine's recall page.
| Engine | Campaign | Years | Risk (NHTSA) |
|---|---|---|---|
| 6.0 Power Stroke | 09V-399 | 2003 | A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING. |
| 6.0 Power Stroke | 05V-270 | 2004-2005 | SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR. |
| 6.0 Power Stroke | 04V-327 | 2003 | IF THE GROUND WIRE IS LOOSE, ELECTRICAL CURRENT MAY FLOW TO THE RADIO SUPPRESSION STRAP CAUSING IT TO HEAT AND POTENTIALLY MELT OR IGNITE ADJACENT COMPONENTS WHICH COULD RESULT IN A FIRE. |
| 6.4 Power Stroke | 07V-139 | 2008 | LACK OF POWER OR ROUGH OPERATION, UNUSUAL NOISES FROM THE ENGINE OR EXHAUST, WHITE SMOKE FROM THE EXHAUST, AND POTENTIALLY A VISIBLE FLAME OUT THE TAILPIPE CAN OCCUR. |
| 6.4 Power Stroke | 07V-140 | 2008 | LONG TERM CONTACT COULD CAUSE WIRE CHAFE, RESULTING IN COPPER WIRE BEING EXPOSED. IF THIS CONDITION OCCURS, THE BATTERY B+ WIRE COULD SHORT TO GROUND INCREASING THE RISK OF A FIRE. |
| 6.7 Power Stroke | 26V-158 | 2020-2022 | High pressure fuel pump failure can cause a loss of drive power, increasing the risk of a crash. |
| 6.7 Power Stroke | 25V-306 | 2025 | A fuel leak in the presence of an ignition source such as hot engine components, can increase the risk of a fire. |
| 6.7 Power Stroke | 24V-957 | 2020-2022 | High pressure fuel pump failure can cause a loss of drive power, increasing the risk of a crash. |
| 6.7 Power Stroke | 22V-256 | 2020 | Debris lodged within the 'Park' mechanism may prevent the vehicle from achieving or holding 'Park,' increasing the risk of a vehicle rollaway and a crash. |
| 6.7 Power Stroke | 22V-013 | 2021 | A fuel leak in the presence of an ignition source can increase the risk of a fire or injury. |
| 6.7 Power Stroke | 21V-536 | 2020-2021 | Driveshaft separation may result in a loss of drive power, or unintended vehicle movement if the vehicle is in park without the parking brake applied, increasing the risk of a crash. |
| 6.7 Power Stroke | 21V-087 | 2020 | An overloaded vehicle can increase the risk of a crash. |
| 6.7 Power Stroke | 20V-365 | 2020 | An engine stall or requiring additional braking effort to stop the vehicle can increase the risk of a crash. |
| 6.7 Power Stroke | 16V-778 | 2017 | If the shield becomes dislodged, the drain valve may open resulting in a fuel leak. A fuel leak, in the presence of an ignition source, increases the risk of a fire. Under certain conditions, significant liquid fuel on the road surface may cause a slip hazard, increasing the risk of a crash. |
| 6.7 Power Stroke | 14V-204 | 2015 | If the vehicle is in "Reverse" while the while the gear selection shows "Drive," unexpected movement could occur, increasing the risk of a crash. |
| 6.7 Power Stroke | 13V-535 | 2011-2012 | An unexpected engine stall increases the risk of a crash. Additionally, if this were to occur when the ambulance is transporting a patient, there is an increased risk of injury to the patient. |
A recall's remedy is free. Whether one is still open on a given truck is a VIN question: check at nhtsa.gov/recalls before paying for the same work.
Repair costs, in money
Parts budgets from our repair recipes, for the failures a recipe prices: Dave's Auto Center's prices where Dave's lists the part, approximate OEM and maker catalog prices (rounded) for the rest. Labor not included; not a quote.
| Engine | Failure | Budget band |
|---|---|---|
| 6.0 Power Stroke | FICM (Fuel Injection Control Module) failure | about $150-$300 in parts (recipe) |
| 6.0 Power Stroke | Fuel injector stiction / failure | about $85-$300 in parts (recipe) |
| 6.4 Power Stroke | High-pressure pump (Siemens K16) destruction | about $2,100-$2,400 in parts, plus parts we have no price for (recipe) |
| 6.4 Power Stroke | DPF clogging / regeneration problems | about $1,400-$2,650 in parts (recipe) |
| 6.4 Power Stroke | EGR cooler failure -> #8 hydrolock | about $1,400-$2,650 in parts (recipe) |
| 6.7 Power Stroke | DEF / SCR / NOx sensor faults | about $110-$4,400 in parts (recipe) |
| 6.7 Power Stroke | CP4.2 high-pressure fuel pump contamination cascade | about $2,100-$7,600 in parts (recipe) |
| 6.7 Power Stroke | Low-pressure fuel supply weakness (lift pump, filters, water-in-fuel) | $300.00 in parts at Dave's Auto Center (recipe) |
| 6.7 Power Stroke | DPF clogging / regeneration problems | about $110-$4,400 in parts (recipe) |
| 6.7 Power Stroke | EGR cooler thermal-fatigue coolant leak | about $270-$910 in parts (recipe) |
| 6.7 Power Stroke | EGR valve soot clogging / sticking | about $270-$910 in parts (recipe) |
| 6.7 Power Stroke | VGT turbocharger failure - generation dependent (ceramic-bearing GT32 vs journal-bearing GT37+) | about $1,850-$2,000 in parts (recipe) |
Going to look at one of these trucks? Decode its VIN for the exact engine, its recalls and failure modes, then take the buyer's checklist with you.
Look up a VIN 6.0 Power Stroke checklist6.4 Power Stroke checklist6.7 Power Stroke checklistMethod: built from the same records as the engine pages on 2026-11-01. Failure modes are tiered and sourced per record and ranked by how widespread they are; complaint counts come from keyword classification of NHTSA owner complaints (unadjudicated); recalls are NHTSA's records for the models and years each engine was sold in; budgets are our repair recipes' bands at their check-date prices. No verdicts here, documented risk only. Full disclosure model.