How To Change The Cover Behind The Water Pump On A F350 6.4l Engine

Most Mutual Issues 6.4L Powerstroke Owners Run into

While the half dozen.4L Powerstroke offered some improvements over the 6.0, they are still largely unreliable. There are a number of common half-dozen.4L Powerstroke Problems that owners of these trucks consistently encounter. What'southward worse is that like the 6.0L Powerstroke, repairing the half dozen.4 often requires raising the cab to hands admission the engine. This makes any repair more expensive.

Thankfully, considering these 6.4L Powerstroke Problems are so common, we now know many of their causes, too as how to gear up them. Most 6.4L Powerstroke Problems are attributed to a poor factory design and new emissions devices. Hither's a list of the virtually common issues found on 2008-2010 Ford Superduty trucks with the six.4L Powerstroke Diesel fuel engine.

xiii Common 6.4L Powerstroke Bug

• Oil Dilution
• Leaking Radiator
• Poor Fuel Economy
• Clogged Diesel fuel Particulate Filter (DPF)
• Chock-full Engine Oil Cooler
• EGR System Failure
• Cracked Pistons
• Cracked Up-Pipes
• Cylinder Washing
• High Pressure Fuel Pump Wire Chafing
• Fuel System Failure and K16 Injection Pump Self-Destruction
• Cracked Blocks
• Front Cover Cavitation

Now that you know the most common problems found on these trucks, it'south time to dive deep into every specific trouble and how to set up them. If y'all desire to skip to a section, simply click on i of the bulleted links. If yous're not looking for a specific problem, simply curl down. Let's go far to it!

i. Oil Dilution

Oil dilution is an extremely common problem that vi.4L Powerstroke owners face. Have you lot ever changed your engine oil on your 6.iv by yourself? Y'all might have been surprised that afterward draining the oil out of your truck, you lot establish a ton of extra oil. Several quarts and sometimes even over a gallon of extra oil tin exist removed when changing your engine oil.

Information technology'south non really oil though. What you're experiencing is oil dilution. That extra liquid is diesel. When your 6.4 undergoes active regeneration, diesel is injected tardily in the exhaust stroke. It and then travels into the exhaust stream, elevates EGTs and burns off hydrocarbons from the diesel particulate filter.

Oil dilution is an unfortunate by-product of this emissions process. What issues tin can oil dilution atomic number 82 to though? Diesel doesn't offering the same lubricating properties as your engine oil does. This can pb to increased habiliment and tear on crucial engine components considering of a lack of lubrication. So how do yous prevent this problem from happening?

The Fix For Oil Dilution

Beginning and foremost, check your engine oil frequently. Once a week take a wait at your dip stick. If y'all're over max oil capacity, change the oil and oil filter immediately. Don't use the 10,000 oil change intervals recommended by your possessor's manual. Instead, change the oil and filter on your 6.4L Powerstroke every 5,000 miles. Also make sure you use high quality oil that meets or exceeds OEM specs. If you're over v,000 miles, here are some high quality 6.4L Powerstroke engine oils and oil filters that yous tin can utilise to practice maintenance immediately.

Motorcraft SAE 15W40 Diesel fuel engine Oil

Can't go wrong with OEM when information technology comes to maintenance. Ane of the best 6.4L Powerstroke engine oils to use is Motorcraft 15W-40 Diesel Motor Oil. This is the preferred engine oil viscosity for climates to a higher place 20 degrees Fahrenheit. If yous are in a colder climate, your truck may require a dissimilar viscosity. Check your diesel fuel supplement manual or your possessor's manual for more information.

Motorcraft FL-2016

Motorcraft Filters are the Merely filters you lot should ever use in your Powerstroke diesel truck. The 2008-2010 6.4L Powerstroke uses the Motorcraft FL-2016 engine oil filter which provides OEM quality filtration and reliability.

On trucks that aren't used on the highway or are strictly used for off-route fun or competitions like sled pulling, deleting the DPF altogether is possible. Deleting your engine's Diesel Particulate Filter stops regeneration from always occurring in the first place. It requires the apply of a straight pipe exhaust organization and a delete-capable tuning device.

2. Leaking Radiators

Unlike the vi.0L Powerstroke, a puddle of coolant underneath your truck isn't because of a blown head gasket. six.4L Powerstrokes are notorious for developing radiator leaks because of the poor radiator design. The crimps on the plastic ends of the radiator tend to separate, causing them to leak. When y'all're losing coolant, you'll often experience overheating which could pb to major problems if not addressed as soon every bit possible. You might also observe visible signs of the radiator leaking.

The Solution for a half-dozen.4L Powerstroke Leaking Radiator

Unfortunately, there isn't a fix for this other than replacing the radiator. Fifty-fifty if your stock radiator hasn't failed yet, it's a good idea to be proactive. Here are some quality 6.4L Powerstroke radiator solutions.

Mishimoto 6.4L Powerstroke Radiator

Want to replace that old, leaky radiator that's currently on your six.4L Powerstroke? Mishimoto's 6.4L Powerstroke Aluminum Radiator offers significantly improved durability because the end pieces are completely welded. This radiator likewise uses safety mounting begs, instead of the solid metal OEM ones, to reduce the corporeality of flex force transferred to the radiator.

To further increment radiator durability, y'all can also get a radiator support bar. Radiator support bars add rigidity and aid prolong coolant arrangement life by reducing front end flex and twisting. Here'southward a high-quality radiator support bar you should consider.

Mishimoto Radiator Upper Support Bar

Mishimoto's Radiator Upper Support Bar helps prevent i of the most common 6.4L Powerstroke Problems. It adds some much needed rigidity to your radiator and reduces the transfer of force and shock to the truck'southward radiator.

3. Poor Fuel Economy

Despite the impressive 6.4L Powerstroke specs and features that make these engines a powerhouse, they lack substantially when information technology comes to fuel efficiency. The major reason for the 6.iv's lack of mpgs is none other than the new diesel particulate filter. Active regeneration uses diesel to increase EGTs and clean the dpf. Unfortunately, that's diesel fuel existence used for something other than propulsion. Urban center driving and driving in heavy traffic make mpgs get down always further as they will result in more frequent active regeneration cycles.

Making A 6.4L Powerstroke More Fuel Efficient

If you want to meliorate fuel economy in your 6.4L Powerstroke you lot're going to take to spend some money. While a straight pipe frazzle and a tuner will profoundly increase your mpgs, deleting or turning off emissions devices is federally illegal on whatever highway driven or registered vehicle. Instead, you're going to want to invest in aftermarket accessories like a cold air intake, aftermarket intercooler, and a programmer or tuner that doesn't delete your emissions devices. Many tuners are now CARB canonical and emissions compliant. Here are some of our favorite mods to increase fuel economy.

Air Dog 2-4G 100 GPH Lift Pump

Want ameliorate fuel economy on your 6.4? What better way to achieve this than by giving your engine cleaner fuel for a more consummate burn. Elevator Pumps similar the Air Domestic dog 2-4G 100 GPH Lift Pump Organization provide significantly better fuel filtration than your truck'southward factory fuel filtration systems. They also supply a steady amount of fuel making them invaluable when you add together tuning! The factory elevator pump often falls brusque of supply your truck what it needs when a tuner is added, starving your truck's fuel injection pump. For higher horsepower engines (500-700 hp) employ the Air Dog II-4G 165 GPH Elevator Pump System instead!

Bully Dog GT Diesel Tuner

The Bang-up Domestic dog GT Diesel Tuner is a popular vi.4L Powerstroke tuner that offers box tunes as well as data parameter monitoring in i parcel!

Cracking Dog/SCT GTX Monitor & Tuner

If you lot desire custom tunes for your 6.4L Powerstroke, the latest products from SCT and Great Dog like the Bully Dog GTX offering custom tuning capabilities that can be received over the cloud. That ways no hooking up to a estimator is required to load tunes onto the device and your truck! Simply remember, the device doesn't come with tunes, you lot have to buy custom tunes from a vendor like Innovative Diesel.

For more information on how to improve performance and reliability on 2008-2010 Ford Superduty trucks with a Diesel fuel engine, visit our thirteen Best 6.4L Powerstroke Performance Upgrades Post.

iv. half-dozen.4L Powerstroke DPF Problems

The primary responsibility of the diesel fuel particulate filter is to capture unburnt hydrocarbons before they exit the tailpipe. While the DPF does this successfully reduce tailpipe emissions on the half dozen.4, they were the first emissions system of this type ever offered on a Powerstroke Diesel engine. Like whatever new design, in that location were a number of common issues found on these early and rudimentary diesel particulate filters.

Mutual vi.4L Powerstroke DPF Issues Include:

• Clogging: Over time the 6.4L Powerstroke's Diesel fuel Particulate Filter can clog. A clogged DPF causes severe restriction in the exhaust organization that needs to be resolved immediately. This occurs when the regeneration process fails to properly clean the Diesel Particulate Filter and often in college mileage engines.
• Leaking: These early on DPFs tin can leak, even shortly afterwards the trucks originally left the dealership.
• Sensor Failure: Sensors are besides prone to failure on the DPF arrangement.

Solutions to DPF Issues

DPF issues are often expensive and require replacement. Leaking or plugged up DPF systems typically require y'all to buy a new one. Unlike Semis and Large-Rigs where the DPF arrangement is designed to be lowered and cleaned, these DPFs are not easy to clean. If your OEM DPF has failed, here are some replacement DPF systems for your 6.4L Powerstroke.

Bully Dog Performance DPF

At present discontinued, the Bully Canis familiaris Performance DPF offers performance gains while also allowing it to be cleaned.

Alliant Power DPF

Another replacement DPF arrangement that is available for the 6.4L Powerstroke is the Alliant Power DPF.

5. Croaky Up-Pipes

Is your vi.4L Powerstroke experiencing excessive soot in the engine compartment? Is in that location soot on the firewall or the hood area? Tin can you hear a loud hissing noise from nether the hood? A very common upshot with the half-dozen.4 is not bad upward-pipes. The cracking occurs on the expansion joints and can cause a huge loss of power, as well as the symptoms listed above.

Solution to Cracked Upward-Pipage Expansion Joints

Unfortunately, your simply selection with cracked up-pipes is to supervene upon them. Don't go with another set of factory upwardly-pipes though! There are enough of aftermarket up-pipes that offer superior structure and even life-time warranties. Bank check out these quality aftermarket up-pipes that should solve the trouble forever!

Rudy'due south Diesel Thick-Wall HD Upwardly-Pipes

Want heavy duty stainless steel replacement up-pipes for your cracked OEM ones? Rudy's Diesel fuel Thick-Wall Up-Pipes are a direct OEM replacement and even EGR compliant!

MBRP Aluminized Upwards-Pipes

MBRP'south Up-Pipage Kit replaces the problematic OEM up-pipes while retaining EGR compliance! They're a direct OEM replacement also!

6. Clogged EGR Coolers

The 6.4L Powerstroke's EGR Coolers reduce the temperature of hot exhaust gases after they are re-routed by the EGR valve. Coolant is used in this process which over time can break down, clogging the EGR cooler. Similar to the 6.0L Powerstroke, half dozen.4s experience EGR Cooler failure frequently. Unfortunately, the 6.4L Powerstroke uses ii EGR Coolers instead of just one. That's two EGR Coolers than tin fail! That's twice the headache!

Preventing Clogging EGR Coolers

As a preventative measure, invest in a coolant filtration system. Coolant breakdown is an inevitable office of the exhaust gas recirculation process. Coolant filtration systems assistance preserve your coolant quality and can drastically increase coolant lifetimes. Mishimoto and Sinister Diesel both make relatively cheap coolant filtration systems.

Mishimoto Coolant Filtration System

Mishimoto's Coolant Filtration Organization is probably the best quality arrangement on the market place. Mishimoto specializes in operation cooling applications and this kit will preserve your coolant quality and it'due south also pretty easy to install!

Brand sure you also follow a severe 6.4L Powerstroke maintenance schedule too. Past changing your coolant frequently, you maintain high-quality coolant flowing throughout your half-dozen.4L Powerstroke's cooling system. Aftermarket EGR Coolers tin can besides offering superior performance and durability compared to factory ones.

Fixing a Plugged EGR Libation

If one, or both, of your OEM EGR Coolers has already plugged upwards, yous can replace them with aftermarket units that are significantly more durable and reliable. Aftermarket coolers often feature a sturdier design to prevent leaking and improved coolant flow to help lower coolant temperatures. Cheque out these EGR Libation replacement systems for the 6.4L Powerstroke.

AFE Bladerunner EGR Philharmonic

AFE Power's Bladerunner EGR Combo is another aftermarket replacement kit for your manufacturing plant six.4 Powerstroke EGR Cooler System.

vii. High Pressure Fuel Pump Wire Chafing

Early model year half dozen.4L Powerstroke are susceptible to chafing on the high pressure fuel pump harness. Over time, vibrations tin can cause the wires to be exposed. Once exposed, you lot run the adventure of shorting your high pressure level fuel pump. That's an expensive repair you don't desire to adventure! Luckily at that place is an easy solution.

Solution

Later on model 6.4 Powerstroke engines don't seem to encounter this problem every bit frequently. Ford was well aware of this problem. They corrected this problem in late model trucks by adding a protective covering to the wire harness. This is one of the reasons later versions of the 6.4L Powerstroke are more desirable than early ones. If you lot oasis't purchased one nonetheless, look for a 2009-2010 model.

If it's too late and the wires on your HPFP are exposed, purchase Ford'due south replacement harness Ford Office # 8C3Z-9G805-B. It'll come with a protective roofing then you won't have the same problem again. Unfortunately, this repair requires the cab to be pulled. The K16 injection pump is hidden and to get access it requires a ton of work.

Ford # 8C3Z-9G805-B

8. Front Cover Cavitation and Leaks

Front cover leaks can develop overtime, which tin can cause coolant to leak into the crankcase. This is another reason it is very of import to check your dipstick oft. Yous can often catch a trouble before information technology leads to a full engine rebuild. Frequently, leaks develop nearly the water pump area. Many believe these leaks occur due to cavitation.

Solution

If you lot accept a front comprehend leak, y'all will have to supplant it. It won't exist a cheap repair either. The best affair you can exercise is be vigilant about your 6.4L Powerstroke's maintenance. Go a coolant filtration device. Invest in quality coolant and the proper SCA/DCA coolant condiment. Make sure you change your 6.4L Powerstroke's coolant as recommend for the manufacturer or even before.

ix. Fuel-Water Separator Issues

Add ane more than line item to your list of mutual 6.4L Powerstroke problems! The fuel-water separator tin clog if you don't drain information technology oft enough. Basically the water and diesel mixture coagulates and creates a sludge that can crusade the drain valve to stick shut. When enough h2o is nerveless it can enter the vehicles fuel system, causing rust and poor fuel quality.

The loftier pressure fuel system used in these trucks are extremely susceptible to fuel organisation failures from poor fuel quality. When rust or poor fuel go to the fuel injection pump, it tin lead to self-destruction of the K16 injection pump which then sends metal shrapnel to your injectors. This tin substantially impale the entire fuel organisation costing thousands and thousands of dollars of repair and a truck that is in the shop for a long fourth dimension.

Solution

The best way to forbid fuel organisation failure resulting from the OEM Water/fuel separator is to bleed it frequently. The more than ofttimes, the better. If you lot need to, drain information technology every other week. This should help maintain the factory organisation for longer.

Another solution to profoundly improve fuel quality and extend fuel system lifetimes is by installing a fuel lift pump arrangement. They offering superior fuel filtration than the OEM system and the result is greater fuel economic system, fuel system longevity, and fifty-fifty meliorate performance. Hither are some quality kits!

Air Canis familiaris Ii-4G 100 GPH Lift Pump Arrangement

For stock to slightly modified trucks, the Air Dog II-4G 100 GPH Lift Pump system provides a consistent supply of fuel and better fuel filtration characteristics than the OEM fuel system. The consequence is long fuel system life and ameliorate overall performance.

Air Domestic dog Two-4G 165 GPH Lift Pump Organization

If your truck is more than than a little modified and you fall in the 500-700 horsepower range, you demand the Air Domestic dog Two-4G 165 GPH Lift Pump System. This system is designed to work with trucks that require a piddling more fuel.

x. Clogged Engine Oil Cooler

Many EGR related failures are actually mis-diagnosed. The real problem yous may be encountering is a clogged Engine Oil Cooler. Clogged Engine Oil Coolers is another ofttimes encountered 6.4L Powerstroke Trouble in which coolant breakdown blocks the passages of the Oil Cooler. The Oil Libation is responsible for cooling your 6.4L Powerstroke's engine oil by using coolant. When these passages go blocked up your 6.4 will feel higher engine oil temperatures, less coolant menstruum to the EGR organization, and the engine tin can frequently derate.

You lot tin ofttimes spot an engine oil cooler that isn't working properly by monitoring your engine's coolant and engine oil temperatures. If in that location is more than a xiv-degree split up between the ii, information technology'southward likely that your engine oil cooler is on its way out.

Fixing six.4L Powerstroke Oil Cooler Problems

Unfortunately, the 6.4L Powerstroke oil cooler isn't able to be cleaned. Instead, you have to replace it. Yous can supervene upon information technology with a Ford OEM engine oil cooler which will probable solve the trouble for another 50-75,000 miles or y'all can use an aftermarket engine oil libation. Aftermarket engine oil coolers oft last longer and provide amend cooling performance than OEM units. Calculation a coolant filtration system like the Mishimoto Coolant Filtration system above is a great mode to better oil libation lifetimes likewise.

Ford OEM Oil Libation

If yous like OEM replacement parts, the OEM Ford 6.4L Powerstroke Oil Libation should give y'all another 50-75,000 problem-gratis miles when you supplant your quondam broken one.

Mishimoto Oil Cooler

Want an affordable, highly-rated half-dozen.4L Powerstroke oil cooler for a great toll? Mishimoto's half-dozen.iv Powerstroke Oil Cooler offers a ton of value at less $200 and comes with a lifetime warranty!

Alliant Power Oil Cooler

Another quality replacement Oil Cooler that will get the chore washed is the Alliant Ability Oil Cooler.

11. 6.4L Powerstroke Cracked Piston Problems

The 6.4L Powerstroke is known for bang-up pistons. Information technology typically happens in higher mileage engines, simply this is tin affect all-mileage 6.4 trucks. If left unchecked even bigger issues can occur, like melted injector tips.

Piston swell is a result of poorly designed pistons that aren't very durable. The OEM pistons feature a fuel bowl, which is where the cracks typically start at the thin border. Then these cracks typically develop and go worse. This crack can and then lengthen across the entire piston.

Fixing 6.4L Powerstroke Piston Bug

Unfortunately, replacing your 6.4L Powerstroke engine's pistons is a very expensive repair which requires engine disassembly. Replacing the OEM pistons with MaxxForce pistons seems to practice the truck. The International MaxxForce 7 engine was used on heavier duty commercial vehicles and therefore was built slightly better. The pistons used on the MaxxForce 7 don't feature the sparse lip that causes piston smashing, making them significantly more reliable than those establish on the 6.4l Powerstroke.

It's Not All Bad

While the half-dozen.4L Powerstroke looks like its non worth the problem, there are many people who swear by these trucks and dear them. The half dozen.4L Powerstroke has impressive operation specs thanks to its twin sequential turbochargers and common runway fuel injection system. Over 500 horsepower tin hands exist achieved inexpensively.

This propensity to become powerful can lead to headaches down the road all the same. Increasing operation ofttimes shortens any engine's lifespan. Information technology's best practise to limit modifications that better performance to unsustainable levels. Proper, frequent maintenance is also strongly encouraged. Treating this engine like the reliable and trusty 7.3L Powerstroke will outcome in a very short lifespan.

Check out our Comprehensive 6.4L Powerstroke Maintenance Guide for detailed information near how to maintain these trucks. It covers recommended maintenance intervals and also lists the parts, fluids, and filters you demand to keep your half dozen.iv on the road!

Other 6.4L Powerstroke Resources

• 6.4L Powerstroke Specifications
• A Guide to half dozen.4L Powerstroke Emissions
• half-dozen.4L Powerstroke Maintenance Guide
• Best vi.4L Powerstroke Operation Upgrades

Source: https://dieselresource.com/diesel-resources/6-4l-powerstroke-problems/

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