Reference

Truck engine repair costs, engine by engine

What the parts cost to fix 81 documented failures on 21 engines, from a sensor to a high-pressure fuel system. Each line links to the failure and to the repair plan with its full parts list.

Parts only, no labor. Parts at Dave's Auto Center are priced exactly; the rest are approximate catalog prices, rounded. A range runs from the cheapest way to fix the failure to the dearest, for example one sensor against the whole assembly. Shop labor can match or exceed the parts on the big jobs.

The biggest parts bills

The ten repairs with the highest top-end parts budget, all engines together. Failures one repair fixes together share a line.

Failure	Engine	Parts budget
CP4.2 high-pressure fuel pump contamination cascade	6.7 Power Stroke (2011-present)	$2,100-$7,600
VGT turbo electronic actuator failure (HE300VG family)	6.7 Cummins 2019+	$1,450-$6,850
Holset VGT turbo sticking / actuator failure	6.7 Cummins 2007-2018	$3,250-$6,000
Bosch CP4.2 high-pressure pump failure and fuel-system contamination	Duramax LML (2011-2016)	$2,350-$5,000
DEF / SCR / NOx sensor faults; DPF clogging / regeneration problems	6.7 Power Stroke (2011-present)	$110-$4,400
Bosch CP4.2 high-pressure pump failure (recall 22V-406)	Ram 1500 EcoDiesel (2014-2019)	$60-$3,500
VGT turbo vane carbon / actuator wear (LLY+)	Duramax LB7-LMM (2001-2010)	$240-$3,250
Common-rail injector wear / nozzle carbon (03-07)	5.9 Cummins (1994-2007)	$2,600-$2,800
EGR cooler failure -> #8 hydrolock; DPF clogging / regeneration problems	6.4 Power Stroke (2008-2010)	$1,400-$2,650
High-pressure pump (Siemens K16) destruction	6.4 Power Stroke (2008-2010)	$2,100-$2,400

Engine by engine

7.3 Power Stroke (1994.5-2003)

Failure	How common	Parts budget	Usually done by	Plan
High-pressure oil pump wear / low ICP	Common	$10-$630	DIY	Repair plan
IPR valve failure / o-ring degradation	Common	$10-$630	DIY	Repair plan
Injector o-ring failure	Common	$10-$630	DIY	Repair plan
Turbo up-pipe / donut gasket leaks	Common	$10-$560	DIY	Repair plan
Turbo pedestal o-ring leaks	Common	$10-$560	DIY	Repair plan
EBPV stuck (exhaust backpressure valve)	Occasional	$10-$560	DIY	Repair plan
Fuel bowl / filter housing leaks and heater short	Common	$10-$560	DIY	Repair plan
Glow plug / glow plug relay failure	Very common	$55-$160	DIY	Repair plan
Under-valve-cover harness (UVCH) failure	Common	$55-$160	DIY	Repair plan
CPS (camshaft position sensor) failure	Very common	$35	DIY	Repair plan

6.0 Power Stroke (2003-2007)

Failure	How common	Parts budget	Usually done by	Plan
Fuel injector stiction / failure	Common	$85-$300	Either	Repair plan
FICM (Fuel Injection Control Module) failure	Very common	$150-$300	DIY	Repair plan

6.4 Power Stroke (2008-2010)

Failure	How common	Parts budget	Usually done by	Plan
EGR cooler failure -> #8 hydrolock	Common	$1,400-$2,650	Shop	Repair plan
DPF clogging / regeneration problems	Common	$1,400-$2,650	Shop	Repair plan
High-pressure pump (Siemens K16) destruction	Common	$2,100-$2,400 plus parts we have no price for	Shop	Repair plan

6.7 Power Stroke (2011-present)

Failure	How common	Parts budget	Usually done by	Plan
CP4.2 high-pressure fuel pump contamination cascade	Common	$2,100-$7,600	Shop	Repair plan
DEF / SCR / NOx sensor faults	Very common	$110-$4,400	Shop	Repair plan
DPF clogging / regeneration problems	Common	$110-$4,400	Shop	Repair plan
VGT turbocharger failure - generation dependent (ceramic-bearing GT32 vs journal-bearing GT37+)	Occasional	$1,850-$2,000	Shop	Repair plan
EGR valve soot clogging / sticking	Common	$270-$910	Shop	Repair plan
EGR cooler thermal-fatigue coolant leak	Common	$270-$910	Shop	Repair plan
Low-pressure fuel supply weakness (lift pump, filters, water-in-fuel)	Common	$300.00	Either	Repair plan

3.0 Power Stroke (2018-2021)

Failure	How common	Parts budget	Usually done by	Plan
CP4.2 high-pressure pump failure (contamination cascade)	Occasional	$90-$1,700	Not stated	Repair plan
DEF heater faults and harness corrosion (P20BA)	Common	$200-$960	Not stated	Repair plan
EGR bypass valve / EGR cooler faults (recall 20E04)	Common	$420	Not stated	Repair plan

5.9 Cummins (1994-2007)

Failure	How common	Parts budget	Usually done by	Plan
Common-rail injector wear / nozzle carbon (03-07)	Common	$2,600-$2,800 plus parts we have no price for	Shop	Repair plan
VP44 injection pump death (24v ISB)	Common	$2,100	Either	Repair plan
Fuel lift (transfer) pump failures	Common	$120-$1,950	DIY	Repair plan
Killer Dowel Pin (KDP) on the 12v P-pump engines	Common	$220-$520	Either	Repair plan

6.7 Cummins 2007-2018

Failure	How common	Parts budget	Usually done by	Plan
Holset VGT turbo sticking / actuator failure	Very common	$3,250-$6,000 plus parts we have no price for	Shop	Repair plan
EGR valve sooting / failure	Common	$650-$2,100 plus parts we have no price for	Either	Repair plan
EGR cooler failure	Common	$650-$2,100 plus parts we have no price for	Either	Repair plan
Lift pump / fuel delivery weakness	Common	$80-$860	DIY	Repair plan
Grid heater 'killer bolt' ingestion	Common	$270-$820	DIY	Repair plan
Water pump failure	Common	$230-$400 plus parts we have no price for	Either	Repair plan
Fan clutch failure (overheat while towing)	Common	$230-$400 plus parts we have no price for	Either	Repair plan

6.7 Cummins 2019+

Failure	How common	Parts budget	Usually done by	Plan
VGT turbo electronic actuator failure (HE300VG family)	Common	$1,450-$6,850	Shop	Repair plan
EGR cooler failure (2019+ 6.7)	Common	$90-$1,200	Shop	Repair plan
DPF/SCR aftertreatment problems (2019+ 6.7)	Common	$90-$1,200	Shop	Repair plan
DEF quality / freezing inducements (2019+ 6.7)	Occasional	$290-$340 plus parts we have no price for	Either	Repair plan

Ram 1500 EcoDiesel (2014-2019)

Failure	How common	Parts budget	Usually done by	Plan
Bosch CP4.2 high-pressure pump failure (recall 22V-406)	Common	$60-$3,500	Not stated	Repair plan
DEF tank / heater faults (frozen-DEF derate cycle)	Common	$230-$2,350	Not stated	Repair plan
EGR cooler cracking and coolant loss (recall 19V-757)	Common	$480-$2,350	Not stated	Repair plan
Crankshaft tone-wheel delamination and engine stall (recalls 20V-475 / 23V-411)	Common	$40-$130	Not stated	Repair plan

Duramax LB7-LMM (2001-2010)

Failure	How common	Parts budget	Usually done by	Plan
VGT turbo vane carbon / actuator wear (LLY+)	Occasional	$240-$3,250	Shop	Repair plan
Head gasket failures (higher mileage / load)	Occasional	$790-$1,150	Shop	Repair plan
CP3 pump / fuel system contamination	Common	$10-$890	Either	Repair plan
EGR cooler clogging / failure (LB7-LMM)	Common	$300-$780	Shop	Repair plan
LB7 injector failures (the defining repair of the generation)	Common	$350-$410	Shop	Repair plan
LMM DPF-era service (regeneration / ash service)	Occasional	$60-$65	Either	Repair plan

Duramax LML (2011-2016)

Failure	How common	Parts budget	Usually done by	Plan
Bosch CP4.2 high-pressure pump failure and fuel-system contamination	Very common	$2,350-$5,000	Not stated	Repair plan
DEF system failures: tank heater, dosing, quality (LML)	Common	$110-$470	Not stated	Repair plan
Glow plug / control module cold-start service (LML)	Occasional	$170-$280	Not stated	Repair plan

Duramax L5P (2017-present)

Failure	How common	Parts budget	Usually done by	Plan
VGT turbo electronic actuator failure (BorgWarner)	Common	$760-$1,700	Shop	Repair plan
DEF system failures: tank heater, dosing, quality (L5P)	Common	$70-$370	Either	Repair plan

Duramax 3.0 (LM2/LZ0)

Failure	How common	Parts budget	Usually done by	Plan
Extended crank / long-crank no-start (air intrusion, check valve, cam wheel)	Common	$50-$550	Not stated	Repair plan
DEF system faults: tank heater, pump/quality (speed-limited derate)	Common	$110-$500	Not stated	Repair plan
Coolant flow control valve failure (active thermal management)	Very common	$330	Not stated	Repair plan
EGR system failures: valve, cooler, wiring (derate-prone)	Occasional	$75-$250	Not stated	Repair plan

ProMaster EcoDiesel (2014-2016)

Failure	How common	Parts budget	Usually done by	Plan
Turbo and charge-air path	Occasional	$370-$1,800	Shop	Repair plan
Glow plugs and module: cold starts	Common	$60-$140	Either	Repair plan

6.2 Boss (gas)

Failure	How common	Parts budget	Usually done by	Plan
Exhaust manifold leaks (broken manifold bolts)	Common	$810	Not stated	Repair plan
Fuel delivery service (in-tank pump / PFI injectors)	Common	$80-$660	Either	Repair plan
Cooling service (water pump / thermostat / degas)	Common	$25-$170	Either	Repair plan
Ignition service wear (16 plugs / coils)	Common	$55-$120 plus parts we have no price for	Not stated	Repair plan

7.3 Godzilla (gas)

Failure	How common	Parts budget	Usually done by	Plan
Exhaust manifold leaks (broken manifold bolts)	Common	$15-$770	Not stated	Repair plan
Cam lobe and lifter (tappet) wear, worst with long idling	Common	$35-$290	Shop	Repair plan
Cooling service (water pump / thermostat / degas)	Common	$25-$210	Either	Repair plan
Ignition service wear (plugs / coils)	Common	$120-$200	Not stated	Repair plan

6.4 HEMI (gas)

Failure	How common	Parts budget	Usually done by	Plan
Exhaust manifold bolt failure / leaks (HEMI tick source #1)	Common	$30-$550	Not stated	Repair plan
Lifter / cam wear (HEMI tick source #2)	Common	$25-$350	Not stated	Repair plan
Ignition service wear (plugs / coils)	Common	$110-$320	Not stated	Repair plan

ProMaster 3.6 (gas)

Failure	How common	Parts budget	Usually done by	Plan
Cooling: water pump, thermostat housing and coolant bottle leaks	Common	$75-$220	Either	Repair plan
Cam/crank position sensors and cam phaser actuator	Occasional	$90-$100	DIY	Repair plan

GM 6.0 / 8.1 Vortec (gas)

Failure	How common	Parts budget	Usually done by	Plan
Hard cold start / fuel delivery wear	Common	$35-$220	Either	Repair plan
Ignition service at mileage: coils, wires, plugs (misfire under load)	Common	$65-$150	DIY	Repair plan

GM 6.0 L96 (gas)

Failure	How common	Parts budget	Usually done by	Plan
Cooling system wear: water pump, fan clutch, thermostat (L96)	Occasional	$40-$380	Not stated	Repair plan
Ignition misfire: coils and spark plugs (L96/LY6)	Common	$85-$240	Not stated	Repair plan
Fuel delivery: pump, injectors, pressure (L96/LY6)	Common	$45-$200	Not stated	Repair plan

GM 6.6 L8T (gas)

Failure	How common	Parts budget	Usually done by	Plan
Cooling system wear: water pump, hoses, thermostat (towing duty)	Occasional	$40-$300 plus parts we have no price for	Either	Repair plan
Ignition service wear: spark plugs and coils	Occasional	$20-$120	DIY	Repair plan

Method: a failure is priced when one of our repair plans names it as what the plan fixes; the budget is that plan's, computed from the prices of its parts on 2026-11-01. Plans that only prevent a failure (a filter routine before a pump fails) do not price it. "Usually done by" is the plan's own DIY-or-shop note. The same budgets appear on the buyer's checklists and the comparisons. How we tier and source facts.