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Recipe - Ford 6.7L Power Stroke Diesel (Scorpion)

Specific Fix build

Reliability tier: aggregated - verify before ordering, see /disclosure/

Aftertreatment repair for the 2011-2022 6.7 (modes DEF / SCR / NOx sensor faults / DPF clogging / regeneration problems): sensors lie first - verify the DPS and EGT sensors before any assembly spend. The DPF is the catalog's 'Catalytic Converter' assembly (LC3Z/HC3Z by chassis), and the DEF pump/injector changed across generations (AL3Z injector; HC3Z pump module gen3). Clean/clear cheap hardware first, assemblies last.

Parts

• DPF Differential Pressure Sensor (current service PN BC3Z-9J460-G) - DPS sensor (BC3Z-9J460-G) - verify before any DPF spend (qty 1)
• Exhaust Gas Temperature (EGT) Sensor, single - EGT sensor (BC3Z-12B591-C, qty 1 layout) (qty 1)
• Exhaust Gas Temperature (EGT) Sensor, 4-sensor set (DPF/DOC bank) - EGT 4-sensor set (AC3Z-12B591-C) where the DOC/DPF layout takes four (qty 1)
• NOx Sensor, Upstream/Front (current service PN DC3Z-9D378-D) - front NOx sensor (DC3Z-9D378-D) (qty 1)
• NOx Sensor, Downstream/Rear (current service PN DC3Z-9D378-C) - rear NOx sensor (DC3Z-9D378-C) (qty 1)
• DEF (Diesel Exhaust Fluid) Injector (current service PN AL3Z-5J281-B) - DEF dosing injector (AL3Z-5J281-B) (qty 1)
• DEF Pump/Sender Module (Emission Reduction System) - gen3 DEF pump/heater module (HC3Z-5J229-B) (qty 1)
• 6.7L Power Stroke Diesel Particulate Filter, Pickup - DPF assembly, Pickup (LC3Z-5H270-F) - assembly path of last resort (qty 1)
• 6.7L Power Stroke Diesel Particulate Filter, Chassis Cab (from 11/18/2019) - DPF assembly, Chassis Cab late (LC3Z-5H270-G) (qty 1)

Install order

1. verify the sensors: DPS and EGT behavior before anything expensive
2. DEF side: injector then pump module by generation
3. DPF: cleaning service where available before assembly replacement
4. assembly replacement by chassis: Pickup LC3Z vs Chassis Cab HC3Z/LC3Z chains

Expected outcome

Sensors honest, DEF dosing in spec, DPF pressures normal, no derates.

Do not

• do not replace the DPF on sensor evidence alone - the DPS/EGT check is the cheapest decision in this recipe

Parts budget

About $110-$4,400 in parts. It depends on what the diagnosis finds; each option below is what you buy together. Prices marked "at Dave's" are Dave's Auto Center's, the same as in his store; the others are approximate prices from OEM and maker catalogs, rounded (a manufacturer's list price can run higher). Parts only, no labor.

• about $370: DPF Differential Pressure Sensor (current service PN BC3Z-9J460-G) (about $370)
• about $150: Exhaust Gas Temperature (EGT) Sensor, single (about $150)
• about $110: Exhaust Gas Temperature (EGT) Sensor, 4-sensor set (DPF/DOC bank) (about $110)
• about $430: NOx Sensor, Upstream/Front (current service PN DC3Z-9D378-D) (about $430)
• about $270: NOx Sensor, Downstream/Rear (current service PN DC3Z-9D378-C) (about $270)
• about $230: DEF (Diesel Exhaust Fluid) Injector (current service PN AL3Z-5J281-B) (about $230)
• about $960: DEF Pump/Sender Module (Emission Reduction System) (about $960)
• about $4,400: 6.7L Power Stroke Diesel Particulate Filter, Pickup (about $4,400)
• about $4,000: 6.7L Power Stroke Diesel Particulate Filter, Chassis Cab (from 11/18/2019) (about $4,000)

DIY or shop: Shop: aftertreatment handling and regen verification.