Common Problems of 6.4 PowerStroke

After the Powerstroke 6.0 version, they came up with Powerstroke 6.4, which is undoubtedly a better and improved version in performance, but still, it has flaws.

This article will be very useful to you whether you're going to purchase Powerstroke 6.0 or you already have it.

Well! Most owners complained that it has a poor design and poor fuel consumption. This version is also more costly to change and repair.

If you have a Ford Super Duty Truck from 2008-10, you may probably come across powerstroke issues. 

So, don't worry; they are all solvable. You have to give some attention and focus to maintain and remove them!

I'll also explain the cause of the most common powerstroke issues and provide the most genuine solution to cure them.

This article covers everything that you need to know if you have a 6.4 Powerstroke version; it will enhance your knowledge and information about this vehicle.

Let's Follow Me Down!

 

What is a Powerstroke 6.4 Engine? 

Actually! The 6.4 is a Ford truck series classic and one of those powerful engines that every automotive lover is familiar with.

It has been available since 1994 and powers several Ford F-series trucks, including the LCF, Excursion, Ranger, and Super Duty trucks.

Well! This engine is no longer produced due to its old-fashioned construction and design. Other engines, such as the PowerStroke V8 6.7L, have taken the market by storm.

Most Common Problems With Powerstroke 6.4

Many users of Powerstroke 6.4 claim that its design is flawed.

So, let's study common Ford 6.4 Powerstroke issues and problems!

Here you go…

Leaking Radiator

The most common issue faced by the 6.4 Powerstroke Engine is Radiator Leaks. Powerstroke 6.4 causes radiator leaks because of poor radiator design.

Generally, this issue of leakage is caused by these two issues:

1. When crimps at the end of the Radiator get separated and loosen, it will cause leakage.
2. Overheating due to coolant loss can also be a cause of leaks.

Don't try to ignore this! It could result in:

• Overheat the engine
• Spark Plugs
• Crack Block
• Blow head Gasket

If extreme weather conditions are encountered, the engine can even fail.

Solution

Recommended solutions for this problem could be:

01. Add Top Support Bar

You can apply this step if your Radiator is still working in quite a good position.

Now, your concern is to prevent crimps from loosening and breaking apart.

• You can try Mishimoto Radistor's Top Support Bar.

That way, you can make it more stable and rigid.

02. Replace Radiator

Here it comes: When your radiator crimps get separated or loosen, you can only replace the Radiator.

• Well, you can try an aluminium radiator from Mishimoto 6.4L Powerstroke.

That way, you can avoid radiator leak problems, and the new one is fully welded and lasts longer than expected.

Oil Dilution

Another common but confusing issue with Powerstroke 6.4 is oil dilution.

• Oil dilution could cause wear and tear on the engine.

Owners of the 6.4 have reported finding several quarts, if not a gallon, of excess oil. 

The truth is, it isn't oil. In actuality, it is diesel fuel. The 6.4 incorporates an emissions mechanism that causes oil dilution.

Let me explain how.

The diluted oil is a diesel fluid, a product of active regeneration.

The desired fluid is not an oil-like lubricant, so it builds upon the wall of the cylinder and damages the engine.

Solution

The most genuine solutions that can help you out with this problem are:

1. Changing oil is more than Ford recommends.
2. Keep checking on dipsite almost every week. 
3. Remember to keep and filter the oil if the oil level increases from maximum capacity.

Changing the oil every 8,000 kilometres is recommended, using high-quality products like Motorcraft SAE 15W40 Diesel Engine Oil.

EGR System Failure

EGR system failure is another problem that often causes problems with the 6.4 powerstroke.

2 EGR coolers are used by Powerstroke 6.4, which can be clogged over time.

These coolers are used to reduce exhaust gas temperature through EGR valves. 

Solutions

Try one of these methods to prevent EGR system failure problems in the 6.4 Powerstroke.

1. Coolant filtration systems are beneficial as they prevent clogging and extend EGR coolers' lifespan.

1. Another good option is replacing your coolant with another one if your EGR is clogged.

1. Also, the maintenance of the EGR cooler is essential for better engine performance and proper exhaust gas management.

Cracks in Exhaust Pipes

There are crack pipes on the list of common problems with 6.4 powerstroke.

Due to poor design, a crack in the exhaust pipe occurs, which goes on for a long time.

These cracks can be seen at expansion Joints.

• Could you not take it easy?
• This problem could result in;
• Excessive Soot
• Loud Whistling Under the Hood
• Cause significant loss of power

Solution

You can try this to repair or remove the issue of exhaust pipe cracks.

1. Exhaust pipes must be replaced with new ones as the only solution.

Several aftermarket exhaust pipes are available on the market, and they are highly recommended because of their long life expectancy and better quality.

Cracks in Piston

Cracks occurring in the piston are also common problems with Powerstroke 6.4.

Cracks in the piston are a terrible effect of bad design, and like cracks in exhaust pipes, they get longer and deeper with time.

Solution

Here is the solution for piston cracks.

1. In the case of a piston, you can completely disassemble the engine to change the affected piston.

2. Stuffing an engine with a new full rack of eight aftermarket pistons is costly.

The solution for cracks in the piston could be more encouraging to do so.

3. If your piston is not working yet, you can focus on its condition so that whenever you have to change or repair any engine problem, you can cover it there.

Oil Cooler Clogging

In Powerstroke 6.4, this problem occurs when oil more excellent outlets get blocked by coolant decomposition.
This blockage will cause the engine to slow down as a precautionary measure, resulting in 6.4L Powerstroke engine difficulties.

Solution

Here are a few tips and solutions for the oil-clogging problem.

1. If your oil cooler is not working, you can check it out.

• Measure the coolant
• Measure engine oil temperature.

2. If there's a difference of 14 degrees between your two coolant valves, then there must be a blockage or chance of it.

3. There is no way to clean your oil cooler outlet well; you can only replace it.

• Install a new OEM Ford Compatible Oil Cooler in place of the old one

4. You can also purchase and use a coolant filtration to expand coolant life expectancy.

DPF Clogging

Next is diesel particulate filter clogging, which is one of the most common problems in a 6.4 Powerstroke.

Design flaws could cause DPF clogging. These flaws are expected because this is the first power stroke with a filter.

Whenever the active regeneration process is not willing to clean the filter properly, it will be clogged over time.

Solution

Here is a workable solution according to the problem condition.

1. If you want to prevent this problem from occurring, you can use it.

• ULSD Fluid
• Oil lubricants

2. But if your DPF system is already clogged, you must purchase a new one.

Low Fuel Consumption

Regarding fuel efficiency, the Powerstroke 6.4 could be the better or better engine.

DPF, the diesel particulate filter, is responsible for low consumption.

A DPF's active regeneration process uses diesel oil.

This process involves exerting raw fuel onto exhaust streams to increase the temperature of gases and clean the DPF.

Solution

It is how you can treat this problem.

1. The first thing you can do is avoid stop-and-go driving.

• There are more flexible solutions for city drivers, so try the second option.

2. Invest money in purchasing and inserting new tools to improve your oil efficiency.

• You can use the Air Dog 11-4g 100 GPH Lift Pump System for that.

Fuel water Separator Problem 

After many common problems in 6.4 powerstroke engines comes the fuel water separator problem.

It contains a Fuel Water Separator, which can clog over time if you drain it when needed.

1. If water is mixed with the fuel, sludge is produced, leading to the drain valve clogging.
2. If water gets into a truck's fuel system, it will oxidise and also cause low fuel quality.

Solution

Try these suggestions to remove the fuel water separator problem in the 6.4 Powerstroke.

1. Regular maintenance and frequent draining of the fuel water separator are the best ways to avoid this problem.
2. If your car is already affected by this issue, you can use the lift pump system.

• Like Air Dog 11-4G 100GPH

Fuel pump cable chafing

In the list of Common Ford Powerstroke 6.4 Problems and Issues, there's now a cable chafing problem.

Powerstroke 6.4 engines that are manufactured earlier than August 2007 would often see the issue of high-pressure fuel pump cable chafing.

Vibration causes this chafing, which might expose the harness wiring and shorten the HPFP over time.

Solution

In that case, the only best solution is to replace the harness and buy a new one.

• You can purchase a new Ford replacement harness that is Part#8C3Z-9G805-B.

This harness will protect your car from chafing because its protective cover is designed to prevent wiring from slipping when exposed to vibration.

Frequently Asked Question

Which year were Ford's 6.4 diesel engines affected?

From mid-2007 until 2010, Ford employed the 6.4 Powerstroke engine in its F-250 and F-550 Super Duty trucks.

Over this time, a number of concerns developed, most of them related to the engine's pollution control systems,

 which underwent considerable changes due to stricter emission laws.

Is Powerstroke 6.4 less efficient?

Not exactly. While the Powerstroke 6.4 is a powerful engine, it has proven unreliable and has poor fuel economy.

Furthermore, issues with damaged radiators and exhaust pipes contribute to its bad image.

How could I increase fuel efficiency in a 6.4 powerstroke?

To enhance fuel economy, utilise aftermarket performance parts and perform regular maintenance to help the engine run more efficiently.

What is the best way to maintain the Powerstroke 6.4?

To maintain it, you can follow these steps.

1. First, performing a general checkup of your powerstroke 6.4 each after 5,000 miles is best.
2. Drain the fuel-water separator every week.
3. Purchase new accessories and products to enhance its life expectancy.

Which radiator issues do appear in the 6.4 powerstroke?

IssuesFuel rail pressure sensor malfunctions, Fan clutch problems, lift pump failures, and thermostat problems are common concerns impacting engine performance and dependability.

Is the Powerstroke 6.4 version better than the Powerstroke 6.0 version?

Not precisely. While the Powerstroke 6.4L has several typical issues, most may be readily avoided with regular maintenance and improvements.

Why does Powerstroke 6.4 have so many problems?

Most of the issues with this engine are related to its design and new emissions to meet severe EPA requirements.

Conclusion

I hope you understand the common problems with Powerstroke 6.4 and how to deal with them.

There are so many things to learn about this engine that it would be a shame if you bought a truck with one and didn't know how to repair it. 

Even worse, not knowing what the problem is when it fails.

So, having at least your beloved vehicle problem information is better.