If you’re looking for a better 6.4 Powerstroke for your truck, it’s worth checking the worst model years. The 6.4 Powerstroke had great features that gave it a competitive edge over other diesel engines. It also delivered better performance and efficiency than many engines sharing the same class.
Unfortunately, this engine didn’t last long – only three years – due to its many issues. As a potential buyer, understanding the worst 6.4 Powerstroke years will help you avoid frustrations down the road.
I delve into the 6.4 Powerstroke years to avoid and the reasons behind it. I’ll also suggest the best model year of this engine you can rely on.
An Overview of the 6.4 Powerstroke
The 6.4 Powerstroke is Ford’s V8 diesel engine released between 2008 and 2010. Ford introduced this engine in 2008 to replace the issues-stricken 6.0 Powerstroke. This new engine addressed problems experienced in the discontinued Powerstroke 6.0.
This engine was quieter, cleaner, and more powerful than any engine International Navistar made for Ford. Compared to its predecessor, the 6.4 Powerstroke reduced NOx emissions by 50 percent. It was also the first engine to utilize factory-made twin turbochargers and a diesel particulate filter (DPF).
Generally, with the help of Navistar, Ford succeeded in producing a reliable diesel engine for trucks. However, this engine was riddled with many problems, leading to its discontinuation in 2010.
The 6.4 Powerstroke is available in three model years:
- 6.4 Powerstroke 2008
- 6.4 Powerstroke 2009
- 6.4 Powerstroke 2010
Answer: 6.4 Powerstroke Years to Avoid
The 2008 and 2009 models are the worst years among the three. The 6.4 Powerstroke 2008 was the pioneer year and faced the most problems. Below is a table showing issues the two worst model years faced.
| Model Year | Problems |
| 2008 | Poor mileage, Clogged DPFs, Acceleration issues, Cracked Pistons, Leaking radiators, Up-pipe leaks, Problematic oil cooler |
| 2009 | Failed DPFs, Oil contamination, Front cover leakages, Fuel system malfunction |
Depending on the problems with these engines, the 2008 model year takes the lead as the worst 6.4 Powerstroke. Then, the 2009 model year follows with fewer problems.
The 2009 model addressed some issues faced in the previous year. However, it still experienced problems that led to poor feedback.
6.4 Powerstroke 2008 Problems
Below, we’ve detailed common issues with the 2008 model year.
Poor Mileage
Driving a truck with a 6.4 Powerstroke in heavy traffic can lead to poor fuel mileage. This problem stems from the engine’s DPF.
The engine uses diesel during the active regeneration process. This helps increase exhaust gas temperature (EGT) and cleans the DPF. That means the engine uses fuel for other purposes besides propelling your truck forward.
The worst part is that driving slowly or in heavy traffic leads to frequent active regeneration cycles. As a result, the engine consumes more fuel, leading to poor mileage.
Clogged DPFs
Another common problem with the 6.4 Powerstroke 2008 is a clogged diesel particulate filter (DPF). This filter’s role is to reduce emissions. Unfortunately, this model year’s emissions clog the DPF, leading to its failure.
With a clogged DPF, the engine’s and turbocharger’s efficiency decreases. As a result, the engine struggles to remove exhaust gasses, putting stress on various components. If you’re driving with a clogged DPF, you’ll eventually experience loss of power and lengthy cranks.
Acceleration Issues
The 6.4 Powerstroke 2008 has two notable acceleration problems. First, the engine emits intolerable smoke when accelerating. Unfortunately, the smoke gets worse as you continue accelerating.
Another problem is that the engine is likely to go off/shut down when you try to accelerate. There’s no known solution to this acceleration issue, so it’s best to keep off this model year.
Cracked Pistons
Another reason you should avoid the 6.4 Powerstroke 2008 is its fragile pistons. This is a manufacturer’s issue due to the unreliable design of the pistons. With time, your truck’s pistons will crack and create multiple problems down the road.
For example, the cracked pistons may lead to heavy exhaust smoke, decreased compression, and loss of power. You’ll need to replace the broken pistons, which will cost you money.
Leaking Radiator
A leaky radiator is another problem in the 2008 model. Its radiator is fragile due to the plastic tank. If exposed to excessive engine vibrations or high temperatures, the radiator will crack and cause the coolant to leak.
Leaking coolant causes the engine temperature to surge, resulting in engine failure. The only solution to this issue is replacing the plastic radiator with an aluminum type.
Up-pipe Leaks
The 6.4 Powerstroke 2008 is prone to up-pipe leaks, resulting in soot accumulation in the engine. The up-pipe gaskets will break down and leak due to age and accumulated miles. When exposed to excessive engine vibrations and heat, the up-pipe breaks and leaks soot in the engine.
Signs of a damaged up-pipe gasket include a loud whooshing sound and heavy smoke coming from the engine compartment.
Problematic Oil Cooler
The oil cooler makes the 2008 model one of the 6.4 Powerstroke years to avoid. An oil cooler minimizes the engine oil’s temperature, preventing the engine from overheating. Unfortunately, this engine’s oil cooler is prone to failure.
A bad oil cooler doesn’t keep oil temperature at a minimum. As a result, the engine temperature goes up fast, which may lead to engine failure.
Common Problems With the 6.4 Powerstroke 2009
The 2009 model rectified several issues experienced in the previous model year. However, a few issues explain why you should avoid it.
Failed DPFs
Like in the 2008 model, the diesel particulate filter in the 6.4 Powerstroke 2009 is likely to clog and leak.
As a result, the engine works hard to get rid of the exhaust fumes, which puts various components under stress. Overlooking this issue results in a reduction in power output and lengthy cranks.
Front Cover Leakages
The 6.4 Powerstroke 2009 is prone to front cover leakages, causing coolant to enter the crankcase. But what triggers this issue? A clogged EGR cooler is the root cause of front cover leaks. When the EGR coolant fails to cool exhaust gasses, the engine overheats and wears out the aluminum cover.
Another potential cause of cover leaks is cavitation. The area around the water pump is more likely to develop holes and leak coolant.
Oil Contamination
Another issue common in the 2009 model is oil contamination, leading to lubrication problems. When changing oil in this engine, you might wonder where the extra oil comes from. Diesel enters the oil system during regeneration. So, the extra oil you see is not oil but diesel residue.
Fuel System Malfunction
Owners of the 6.4 Powerstroke 2009 have to grapple with the fuel system malfunction, which results in poor mileage. The engine’s fuel system is prone to leaks and component failure. For example, the fuel injection system will fail over time and leak fuel.
Answer: The Best 6.4 Powerstroke Year
If you prefer working with the 6.4 Powerstroke, go for the 2010 model. By this time, Ford had addressed most of the problems reported in the previous model years.
The 6.4 Powerstroke 2010 had fewer issues and performed better than the 2008 and 2009 models.
Its fuel mileage increased, with some trucks, like the 2010 F-250 Super Duty Lariat, getting around 15 MPG. That’s unlike the previous years, which provided around 13-14 MPG.
Wrap Up
The 2008 and 2009 models are the worst 6.4 Powerstroke years to avoid. The 2008 model has the most problems like poor mileage, acceleration issues, clogged DPF, leaking radiator, and problematic oil cooler. Then, the 2009 model follows the line with fewer but troublesome issues.
If you’re in the market for a reliable 6.4 Powerstroke engine, consider the 2010 model. This engine has fewer problems than the two previous years. It also comes with increased fuel mileage and better performance.