Before you actually read the facts below, I was discussing this issue with Brian, the man at GotEngines.com and asked him how one would know if, when a used Ford diesel engine was purchased from his company if it had the upgrades to solve the problems listed below. I got an easy answer to that. Apparently GotEngines.com checks serial numbers and update codes on all used engines of this ilk to make sure they only sell the upgraded engine versions.
With that on mind, the 6.0-liter Power Stroke engine has been troublesome from the day it was launched in the fall of 2002. It replaced a somewhat unrefined 7.3-liter diesel.
The engine was built by longtime Ford diesel supplier, International Truck and Engine Corp., of Melrose Park, Ill.
For this version of the engine, International Truck designed a unique high-pressure fuel-injection system.
Most auto companies use only a fully electronic control system to operate the fuel injectors in what would be a common fuel injection system. International redesigned the Power Stroke’s fuel injectors by using a high-pressure oil pump as well as normal electronics.
I was looking at several of the 150-plus complaints posted on the Web site of the National Highway Traffic Safety Administration, some trucks never even made it home from the dealership before the fuel injectors or turbocharger failed.
The engine also has been plagued with other issues: with leaky fuel injectors, oil leaks, broken turbochargers, wiring harness troubles, faulty sensors, defective exhaust gas recirculation valves and bad computers.
Since the engine was introduced three years ago, Ford has issued at least 77 technical service bulletins. Obviously this is far above average, even for a new engine. These bulletins tell mechanics how to diagnose and fix various problems.
Looking further at the reports I noticed there have been eight service bulletins for GM’s Duramax diesel V-8 and none on record for the Dodge Ram truck diesel engine. Both engines debuted at similar time frames as the Ford Power Stroke.
After just a year on the market, International claims to have almost completely redesigned the Power Stroke’s fuel system, replacing or redesigning nearly ’500′parts. That helped reduce the number of problems, but did not cure the engine of all its ills. Ford has voluntarily recalled the engine at least twice to fix various problems.
Although International claims the engine has be made reliable and trouble free with the extraordinary amount of updates made specifically for this power-plant the problems have caused some troubles and a rift in relations between Ford and International and Fords customers.
Why would you buy a new truck if you knew it needed upgrades to be reliable. If I wanted to have to upgrade an engine I would buy a used car or truck. New is new, unused, not needing upgrades.
Supposedly the engine is more complex than it’s predecessors and requires outstanding diagnostic capabilities to properly identify and repair the faulty parts.
The upside to all of this is that the problems have been solved and can be applied to an pre-upgraded engine. All new and rebuilt engines come with the upgrades too. This is more than one reason for our GotEngines.com Blog: Number one-identifying the most reliable versions of whatever engine you may be intersted in, and Number 2-having use-able information for repairs and decision making, when it comes to home-based car repairs.
I sure miss the 7.3 We have older units in our fleet with the 7.3 Liter that have 300,000 miles on them. Although they are not trouble free they are the original engines. Our 6.0′s have been a nightmare. But I guess you can call it job security!
[...] the introduction of the Ford 6 liter diesel there have been a lot of reliability issues. The people who know more than me about diesel engines in particular agree that when you increase [...]
I have a 2004 6 litre 100,000 km and 3 days over warranty. It has had 2 new egr’s and many oil leaks as well as a charging sysyem that seems to work only when it feels like. It now has egr failure and the dealer says possible head gasket problems to the tune of $7000.00 Cdn. Ford has turned me down re helping on the bill as they say my maintenance records are not good enough.All fluid & filter
changes are documented in my owners manual but they say this is not good enough.I have been doing my own maintenance since I was 16 years old and working in a Texaco service station. I am now 60 years old.This vehicle is my 11th Ford and have been driving them all my life most being new off the lot or ordered from the factory .I am sad to say we will be selling this truck .Our 1999 V10 was problematic i.e always at the dealer who was extremely helpful and now this .A $7000.00 bill for a truck 3 days out of warranty and 100,000 Km or 60,000 miles .Bye BYe senior Henry.p.s When the problem was first noticed i.e vapour out the exhaust I made an appointment with the dealer .The truck was still under warranty.I drained the water seperator and the vapour quit,so I cancelled the appointment .Just over 1 month later it started again,so I called the dealer right away[3 days to late ],even though there is a service bullitin re this problem.Ford and Navistar or International know about this.Maybe this is why North American manufacturers are in trouble
[...] The 6 liter Ford diesel has had an unusual amount of serious problems. In fact, that particular engine is the main topic on most Ford truck forums. As far as I know, many of the built in problems with the engine, which, BYW is manufactured by International, have been worked out. Some of the problems required extensive re-engineering to solve. It is absolutely in your best interest to buy a rebuilt engine, especially the Ford 6.0 Liter engines that has been rebuilt with the latest updates built into them. [...]
the current position that ford is in with the 6.0 ,6.4 is sad.AS a construction fleet mechanic ,I can say we have switched back to gas powered f series pickups. Ford and Navistar only recognize a problem if it is customer pay.The 7.3l engine witch we still use have outlasted the truck chassis ,the engine runs fine at 450-500 thousand but the truck is junk.NO they have not been maintance free but have offered good value to maintance cost over all.the 6.0l engine have yet to exceed 125 thousand without major component failures.Ford also said this engine was tested for 250 thousand miles like the new 6.7l claims.The 6.4l ,we use 12 of them are plaqued
with cylinder head +gasket failures.The nice thing with this engine is you have to pull the cab,to change the turbos or service the heads. Is the 6.7l any better , who knows but we will not be fords test mule any more.Ford needs to make the previous engines right and satisfy the customer not just move on to the next victims.
At my work we hav one 7.3 left an its the best most reliable truck compared to the 5 6.0s we have, the body on the 7.3 is crappy but the motors still goin at 330000miles, i dont know if this new motor that is coming out will be any good, i think it will be better but will still hav a lot of problems the first 2 years its released, i wish they could bring the 7.3 back but it would never pass emmisions, if i were going to buy a truck now it would be a cummins
So Sad To Say Auto makers down care about us…
But They Should cause we pay there saleries By Buying The Junk They Put Out, meaning the ford 6.0 Ford Motor …. you would Think They would Stand By Them..Very sad When U Know Your Service manager by first name…….
Everyone At Ford even The Dealers Know they have a Big Problem… Would Be Nice To walk In There And have Them say Yes the 6.0 Is trouble And We Will Do Everything To Fix The Proble…
If Someone Starts a Law Suit Against Ford Lies, Please Let ME Know…. I Have A 2005 6.0 With 38,000 miles and it has Been Back A few times.. Last time they Had To Rebuild The Turbo( Bad design ) They Should Come Up With A Better Turbo , egr and a head gaskets( Be Responsable) for what they sell.. Let The Go After International………
Ford Power-Stroke Diesel Issues.. | GotEngines.com Auto Engines ……
[...]… if it had the upgrades to solve the problems … debuted at similar time frames as the Ford Power Stroke. … 7 Responses to “Ford Power-Stroke Diesel Issues..”[...]…