6.4 Powerstroke Years to Avoid – Prosource Diesel (2024)

The 6.4-liter Powerstroke engine was very short-lived. It was put in Ford trucks beginning in 2007 for the 2008 model year and the last production year was 2011 for the 2010 model year.

The 6.4 Powerstroke came after the 6.0 Powerstroke, which was widely panned for its problems and poor performance. The issues with both of these engines eventually led to the end of the working relationship between Ford and Navistar and led to Ford designing its next diesel engine in-house.

Numerous problems plagued the 6.4 Powerstroke including up-pipe leaks, radiator problems, weak pistons, DPF clogging, and issues with the oil cooler among many others issues.

ProSource Diesel takes a look at the problems with the 6.4 Powerstroke and the years to avoid.

Is the 6.4 Powerstroke a Good Engine?

Introduced in 2008 to replace the 6.0 Powerstroke, the 6.4 Powerstroke was supposed to improve on the previous engine. It was designed to be more reliable, perform better, and address emissions standards.

However, this goal wasn’t exactly realized as all models of the engine have been plagued with problems. Many of the issues with this engine can be addressed with the replacement of factory parts with 6.4 Powerstroke performance parts.

Despite this, it’s hard to argue that the 6.4 Powerstroke was a good engine right from the start. There are many reasons why it only lasted a few years.

How Much Horsepower Does a 6.4 Powerstroke Have?

Out of the box, the 6.4 Powerstroke was rated for 350 horsepower, but it’s possible to get as much as 500 horsepower or more by replacing stock parts with 6.4 diesel performance parts. The successor to the 6.4 Powerstroke was the 6.7, rated for 390 horsepower.

One of the main reasons for getting a diesel engine is that it can typically be modified to increase horsepower, and the 6.4 Powerstroke is no different.

What Problems Does the 6.4 Powerstroke Have?

The 6.4 Powerstroke wasn’t all bad. In fact, it had some good, strong parts like the bed plate and some of the strongest OEM rods in any light-duty diesel engine.

The high-pressure fuel pump was also a good part that had 20% more flow than its rivals at the time and more than its successor in the 6.7 Powerstroke. But the problems are why we’re here, so let’s dig in.

DPF Clogging

The DPF system works to decrease harmful emissions from a diesel engine, but they can get clogged, which will decrease efficiency and cause problems with the turbocharger. This was a significant problem with the 6.4 Powerstroke, especially in the beginning. If you are having this problem, you could try unclogging it with a DPF cleaner and a DPF cleaning kit.

Oil Cooler Failure

The purpose of an oil cooler is to keep the engine oil temperature at a reasonable level so that the engine won’t overheat. A clogged oil cooler is a common problem on the 6.4 Powerstroke and it can result in overheating.

Weak Pistons

One of the more infamous problems on the 6.4 Powerstroke is its weak pistons that were prone to early cracking. A cracked piston allows extra air into the cylinder, which then decreases the compression ratio. This results in a loss of power and can only be fixed by replacing the pistons.

Leaky Radiator

The stock radiator on the 6.4 Powerstroke didn’t hold up well against regular wear and tear. It often develops leaks, which means a loss of coolant that leads to overheating. The stock radiator is one of the parts that should be replaced with an aftermarket 6.4 radiator.

Oil Contamination

Fuel-contaminated engine oil was another problem with the 6.4 Powerstroke. In this scenario, fuel dilutes and contaminates the engine oil, which reduces the oil’s ability to lower the engine temperature.

A common scenario for 6.4 Powerstroke owners was to find a ton of extra oil during an oil change. However, it’s not actually oil, but diesel fuel that has mixed in with the oil.

Up-Pipe Problems

The 6.4 Powerstroke was also known for developing cracked up-pipes. The telltale sign of this problem is excess soot on your firewall or hood. Cracked up-pipes cause a major loss of power and the only way to deal with this is to get a 6.4 up-pipe replacement.

6.4 Powerstroke Problems By Year

Even though all years of the 6.4 Powerstroke were problematic, the main year to avoid was 2008, which was the first year it came out. The 2008 model was plagued with problems that mainly involved the emissions systems, which were frustrating and costly to fix.

Steps were taken to fix some of the emissions problems in 2009, but new problems with the fuel system cropped up in its place. The 2010 models saw issues with the 6.4 Powerstroke turbo parts and exhaust system.

The good news is that trucks with the 6.4 Powerstroke that are still on the road have probably had a lot of stock parts replaced with quality aftermarket parts. If you own a truck with the 6.4 Powerstroke, chances are you’ve probably already encountered some or all of these problems.

Out of the box, the 6.4 Powerstroke wasn’t a very good engine, but you can rely on ProSource Diesel to find quality aftermarket parts, including new turbo parts, and take advantage of this engine’s strong foundation.