The 6.4L Power Stroke is the V8 turbo diesel Ford used in 2008 to 2010 Super Duty trucks. It was Ford’s first diesel with a factory diesel particulate filter and a high-pressure common-rail system. The most commonly reported 6.4 Power Stroke problems are radiator leaks, EGR cooler failures, fuel in the oil from particulate filter regeneration, high-pressure fuel pump and injector failures, up-pipe leaks and, in severe cases, fuel system contamination that sends debris through the whole system.
Common 6.4 Power Stroke problems
| Problem | Signs |
|---|---|
| Radiator leaks | Coolant loss and overheating; the radiators are a known weak point |
| EGR cooler failure | Coolant loss with no visible leak, white smoke; see diesel white smoke |
| Fuel in the oil | Rising oil level, thin oil; linked to regeneration strategy and injector issues |
| High-pressure fuel pump and injectors | Hard starting, low rail pressure codes such as P0087, misfires |
| Up-pipe leaks | Exhaust leaks, turbo noise, lower boost |
| Fuel system contamination | Pump failure sending metal through the rails and injectors |
Fuel system contamination
When a high-pressure pump fails internally, metal debris can travel through the fuel rails and into every injector. Replacing only the pump leaves contamination behind, so a full fuel system replacement is usually required. We list the Alliant Power reman fuel contamination kit for 2008 to 2010 6.4L Super Duty at $5,506.94. Water and poor fuel are the usual triggers, so keep filters changed and drain the water separator; see fuel filter.
Coolant problems
Coolant loss on a 6.4 is usually the radiator or the EGR cooler. A pressure test finds external leaks; a coolant loss with white smoke and no external leak points to the EGR cooler. Repair with correct parts and keep the emissions system intact; see losing coolant but no leak.
Fuel dilution
Particulate filter regeneration injects extra fuel, some of which can reach the oil. Check the oil level regularly and shorten change intervals if it rises; see bad diesel injector symptoms.
Maintenance that matters
- Change fuel filters on schedule and drain the water separator; fuel quality protects the high-pressure system.
- Check the oil level often and shorten intervals if fuel dilution raises it.
- Watch the coolant level and pressure-test early at any loss.
- Inspect up-pipes and turbo connections for soot traces.
Is the 6.4 reliable?
It is powerful but known for costly repairs. Maintenance records, fuel quality and coolant history matter most when buying one. See how long diesel engines last, Cummins vs Duramax vs Power Stroke and 5R110W problems for the transmission behind it.
More guides: water in diesel fuel.
Trouble codes: P0611 Injector Control Module Performance · P0093 Fuel System Large Leak · all OBD2 codes.
Shipping is a flat $80.00 per order to US addresses, with 15-day free returns. Questions? Ask a parts specialist.