Can yopu Bulletproof a Ford 6.4L Powerstroke diesel? Let's find out. From the years 2008, 2009, 2010, Ford used the 6.4L diesel in light and medium duty trucks.

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While the 6.4L Power Stroke production run only lasted a few years, International's last engine for the Ford Super Duty proved to be a pace setter in the light duty truck market during its production. The greatest complaint from 6.4L Power Stroke owners is poor fuel economy, but the engine does have some issues that have surfaced frequently enough to be characterized as common. Regardless, the engine was considered an improvement over the 6.0L Power Stroke and suffers far less in the reliability department.

Fuel Dilution of the Engine Oil

During the active regeneration process, fuel is introduced into the exhaust stream by means of a post-injection strategy, in which fuel is injected late in the exhaust stroke so that it may exit the cylinder in its raw (or relatively so) form. This method, as opposed to the "9th injector" design that relies on a dedicated fuel injector mounted in the exhaust system, causes fuel to stick to the wall of the cylinder where it is carried into the crankcase.

Fuel dilution is a common and quite significant problem in the 6.4L Power Stroke, as diesel fuel does not provide near the lubricating properties as engine oil. But fuel dilution is also normal and to be expected from this system. In order to prevent possible damage from excessive fuel dilution, owners should check the engine oil frequency and consider changing their oil more frequently than Ford recommends. Many owners follow Ford's "Severe" maintenance schedule regardless of driving patterns, which cuts the oil change in half. If you find that the oil level in the crankcase is increasing, have your oil changed immediately.

Cylinder Washing

Cylinder washing is a concern very much related to the fuel dilution of engine oil. While the active regeneration process is in progress, fuel injected late in the exhaust stroke has a tendency to "wash" the cylinder, diluting the thin layer of protective engine oil lining the cylinder. While this hasn't been associated with any significant percentage of engine failures, it's obviously less than ideal for the longevity of the 6.4L Power Stroke.

Leaking Radiator

Leaking radiators are common and more prominent on early build engines - it seems as though the problem was addressed and eradicated in later production engines. Leaks commonly develop at the ends of the radiator where the crimps holding on the end tanks work loose overtime. New radiators do not typically develop leaks like the early design, although replacing one can be rather expensive.

Fuel-Water Separator Issues
DPF Clogging
Wire Chafing at High Pressure Fuel Pump (HPFP)
Cracked Exhaust Up-pipe Expansion Joints
Cavitation Wearing Holes in Front Cover

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