The Ford 6.4L Powerstroke diesel engine, produced from 2008 to 2010, was intended to be an improvement over its predecessor, the 6.0L Powerstroke. However, this engine quickly gained a reputation for being problematic and unreliable. For truck enthusiasts and potential buyers, understanding which years of the 6.4 Powerstroke to avoid is crucial for making an informed decision.
The 6.4L Powerstroke was only in production for three model years: 2008, 2009, and 2010. While all years of this engine are known to have issues, the 2008 model year is generally considered the most problematic. This is primarily due to it being the first year of production, where many design flaws and reliability issues were yet to be addressed.
| Model Year | Reliability Rating |
|---|---|
| 2008 | Poor |
| 2009 | Below Average |
| 2010 | Below Average |
Common Problems Across All 6.4 Powerstroke Years
While the 2008 model year is often cited as the worst, all years of the 6.4 Powerstroke share common issues that potential buyers should be aware of. These problems range from minor inconveniences to major engine failures that can result in costly repairs.
One of the most prevalent issues is oil dilution. This occurs when diesel fuel mixes with the engine oil, reducing its lubricating properties and potentially causing severe engine damage. Owners often report finding excessive amounts of oil during changes, sometimes up to a gallon more than expected. This problem is related to the engine’s regeneration process, which injects additional fuel into the exhaust stream to clean the Diesel Particulate Filter (DPF). Some of this fuel can make its way into the oil system, leading to dilution.
Another common problem across all years is radiator leaks. The stock radiators on the 6.4 Powerstroke are prone to developing leaks, which can lead to coolant loss and engine overheating. This issue is particularly concerning because overheating can cause severe damage to the engine, including warped cylinder heads or cracked engine blocks. Regular inspection of the cooling system and prompt replacement of the radiator at the first sign of leaks is crucial for maintaining engine health.
The Exhaust Gas Recirculation (EGR) system is another trouble spot for the 6.4 Powerstroke. This emissions control system is designed to reduce nitrogen oxide emissions by recirculating a portion of the exhaust gases back into the engine. However, the EGR coolers are prone to clogging and failure, which can lead to coolant loss and potential engine damage. Many owners opt to delete the EGR system entirely, though this modification is not legal for on-road use in many jurisdictions.
2008 Model Year: The Most Problematic
The 2008 model year of the 6.4 Powerstroke is widely regarded as the least reliable and the year to avoid if possible. As the first year of production for this engine, it suffered from numerous teething problems that were not fully resolved until later model years.
One of the most significant issues specific to the 2008 model was the high-pressure fuel pump (HPFP) wiring harness. The wiring for this critical component was prone to chafing against other engine parts, leading to exposed wires and potential short circuits. This could cause the HPFP to fail, resulting in a no-start condition or sudden loss of power while driving. Ford issued a recall for this problem, but many 2008 models may still have the original, problematic wiring harness if they haven’t been serviced.
The 2008 models also experienced more frequent failures of the Diesel Particulate Filter (DPF) system. This emissions control device was new to Ford’s diesel lineup, and the early implementation had several flaws. The DPF would clog more quickly than expected, leading to reduced engine performance, poor fuel economy, and in some cases, engine damage if not addressed promptly.
Additionally, the 2008 model year seemed to have a higher incidence of piston failures. The pistons in the 6.4 Powerstroke are known to be a weak point, but the 2008 models appeared to suffer from this issue more frequently. Cracked pistons can lead to a loss of compression, reduced power, and in severe cases, complete engine failure requiring a full rebuild or replacement.
Improvements in 2009 and 2010 Models
While the 2009 and 2010 model years of the 6.4 Powerstroke still had their share of problems, they did see some improvements over the 2008 model. Ford made efforts to address some of the most glaring issues, particularly those related to the emissions control systems.
The DPF system saw some refinements in the later years, with improved regeneration strategies that helped reduce the frequency of clogging. However, this system remained a weak point and continued to cause issues for many owners. The HPFP wiring harness problem was also addressed, with improved routing and protection to prevent chafing and short circuits.
In 2010, Ford introduced some updates to the turbocharger system, which helped improve reliability somewhat. However, these improvements were relatively minor, and the 2010 model year still suffered from many of the same fundamental issues as the earlier years.
It’s worth noting that while the 2009 and 2010 models may be slightly more reliable than the 2008 version, they are still considered problematic compared to other diesel engines of the era. Potential buyers should approach any 6.4 Powerstroke with caution, regardless of the model year.
Alternatives to Consider
Given the widespread issues with the 6.4 Powerstroke, many potential buyers may want to consider alternatives. The 7.3L Powerstroke, which preceded the 6.0L and 6.4L engines, is widely regarded as one of the most reliable diesel engines ever produced by Ford. While it may lack some of the power and modern features of newer engines, its durability and simplicity make it a popular choice for those seeking a dependable workhorse.
For those who prefer a more modern engine, the 6.7L Powerstroke that replaced the 6.4L in 2011 is generally considered a significant improvement in terms of reliability and performance. While early models of the 6.7L had some issues, particularly with turbocharger failures, these were largely resolved in later years, making it a much more dependable option than the 6.4L.
Alternatively, buyers might consider diesel offerings from other manufacturers. The Cummins engines used in Dodge/Ram trucks and the Duramax engines found in GM vehicles are often praised for their reliability and performance, offering viable alternatives to Ford’s troubled 6.4L Powerstroke.
FAQs About 6.4 Powerstroke Years To Avoid
- Which year of the 6.4 Powerstroke is the worst?
The 2008 model year is generally considered the least reliable and most problematic of the 6.4 Powerstroke engines. - Are there any good years for the 6.4 Powerstroke?
While 2009 and 2010 models saw some improvements, all years of the 6.4 Powerstroke are considered problematic and should be approached with caution. - What is the most common problem with 6.4 Powerstrokes?
Oil dilution is one of the most prevalent issues, along with DPF system failures and radiator leaks. - How long do 6.4 Powerstroke engines typically last?
With proper maintenance, a 6.4 Powerstroke might last 200,000-250,000 miles, but many fail much earlier due to inherent design flaws. - Is it worth buying a used truck with a 6.4 Powerstroke?
Given the known issues, purchasing a used 6.4 Powerstroke is risky and not recommended unless you’re prepared for potentially expensive repairs.