Ford Power Stroke Problems Across Generations

Ford Power Stroke Problems Across Generations

Ford 6.7 Power Stroke Problems (2011 – 2016)

Ford always rectified problems with their engines and upgraded them. Ford designed this engine, especially for trucks, so the main objective was to enhance the engine’s performance. The upgrades turned the Ford Power Stroke into one of the most effective hauling and towing machines in the market. However, despite the modifications, there are some problems that you should keep an eye out for.

● EGR cooler: During the new design development, the EGR cooler’s position was shifted to make it easier and less expensive for replacements. The company changed the cooler’s build to a cartridge system for easy replacements, but it is still prone to the most common causes of cooler failures. Expansion and contraction of metal are the primary issue.
● Exhaust system: This is perhaps the most prominent issue with the Ford Power Stroke. The Exhaust Gas Temperature sensors fail very frequently. The sensors trip very often with rising temperatures, and that’s why this part comes with an extended warranty.
● Oil cooler: The new design-installed oil coolers are comparatively weaker than the older versions. The new oil coolers are more fragile and have performance issues while keeping the oil temperature in check. You should get bigger oil coolers for the engine. Installation of the new coolers is not a problem as the OEM mounting points can be used.

Ford 6.4 Power Stroke Problems (2008 – 2010)

This new engine was an upgrade from the 6.0l Power Stroke. It consisted of enhanced ECU changes. However, the upgradation came with their new set of problems and issues.

This new engine faced some issues, which are:

● Diesel particulate system: The function of the particulate system is to capture the soot from the exhaust. At saturation, the diesel is used to burn the excess soot, known as the regen mode. Over time, the whole filter system may break down, increasing the diesel intake considerably and damaging the exhaust as well.
● EGR cooler: This version of the engine added another cooler to the setup for dividing the thermal load among themselves. Despite the improvement, these coolers are still prone to cracking and damage at high temperatures.
● Oil cooler: The oil coolers can get clogged after prolonged use. In this version, the cooler is installed under the turbo engine, which becomes very expensive and difficult to replace.
● Water pump issues: Despite the upgrades in the new version of the engine, the water pumps’ cracking issue persists.
● Cooling system problems: The joints of the new cooling system are prone to developing cracks. This happens mostly at the points where the plastic parts meet the aluminum.
● Cylinder head problem: The clamps and bolts used in this engine’s cylinder head are not sturdy enough to provide adequate support. So, you may need to get them replaced after a short time.

Ford 7.3L Power Stroke Problems (1994-1997)

This version of the Ford Power Stroke had almost the same design as that of the earlier engines. The indicators fired once or twice, depending upon the machine cycle. This led to the engines having less wear and tear. Although the new model’s durability was improved, it reduced the horsepower and the torque of the engine by more than 50%.

Ford 6.0 Power Stroke Problems (2003-2007)

The 7.3l Power Stroke model had an improved design, but the torque and horsepower reduction made it vulnerable to being toppled by other engines. This model came with some issues, which are:

● EGR cooler: The EGR cooler in this engine is undersized from the general models, so it breaks down more frequently than other engines.
● Oil cooler: The oil cooler used in this engine has very small pipes that make clogging and damage of the oil coolers much easier.
●Water pump problems: The water pump used in this engine’s version has a plastic injector. Continuous use and high temperatures can damage the plastic, thereby causing the water pump to fail altogether.
●Cylinder heads and other bolts: In most of these engines, head gas casket failure is a common issue. The main cause behind this is the weak cylinder heads and head bolts that do not offer sufficient clamping force.
●Cooling system issues: The radiators of the cooling system in this engine can crack at the seams. This makes this version’s cooling system more susceptible to failure as compared to other models.

Ford 6.7L Power Stroke Problems (2017 – 2019)

This is the older design carried over to 2017, but the design was completely modified. The company enhanced the engine’s intake and exhaust capabilities, thereby increasing the torque production rate. This version of the engine does not suffer from many issues, but the EGR cooler’s problem persists. Apart from that, the oil cooler faces some issues when operating under heavy towing.

Ford 6.7L Power Stroke Problems (2020-Today)

This is the upgraded version of the previous 6.7l engine. The new design is built upon the previous one instead of changing it. The most significant change is the replacement of the aluminum pistons with steel pistons. This reduced friction and increased strength without changing the engine’s weight. No significant issues have been spotted yet since it’s the latest version. However, the engine’s EGR coolers are still prone to the issues as earlier, albeit to a lesser extent.

Ford 3.0L Ford Power Stroke Problems (2018 -2019)

This version of the engine was introduced especially for some of the top trim models in the market. However, there were some major issues with the engine, causing the manufacturer to discontinue it only after two years. Since this model has completely dropped off the market, the engine’s exact problems are hard to pinpoint.

General Ford Power Stroke Problems

There have been many improvements and changes in the Ford Power Stroke engines over the generations. In all these years, from the data accumulated, some general problems have been identified, which are:

● EGR cooler: In almost every iteration of the engine across the generations, the EGR cooler has been a significant issue in all Ford engines. The build of the EGR cooler makes it more sensitive to damage, especially during heat cycles.
● Oil cooler: The construction of the oil cooler in most of the engine’s iterations has been fragile. Several factors, like the design, the shape, and the oil cooler’s construction, make it easy to get damaged. Changing to an air cooler might be a viable option and more efficient as well.

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