01
CP4.2 fuel pump failure
Sudden no-start with metal debris spread through the entire fuel system — catastrophic and expensive.
The fixInstall a CP4 disaster-prevention bypass kit, or convert to a proven CP3 pump.
2011 – Present
6.7L Power Stroke: Top 10 Problems & Fixes
Ford's in-house 6.7L is powerful and refined, but the CP4 fuel pump and emissions hardware need attention. Protect the fuel system and stay on top of the front end, and these trucks make huge, reliable power.
The 10 most common failures
What goes wrong on the 6.7L Power Stroke — and how we fix it
Ranked from the problems we see most. Every one has a real, root-cause fix — not a band-aid.
02
Early VGT turbo failure
Lost boost and noise from the first-gen ceramic-bearing variable-geometry turbo.
The fixRebuild or upgrade to a stronger turbo on the affected early trucks.
03
DEF system & sensor faults
Warning lights, derate, and countdowns from failed DEF injectors, heaters, and NOx sensors.
The fixDiagnose and replace the failed DEF/emissions component (or delete for off-road use).
04
Clogged DPF & regen issues
Frequent regens, poor economy, and limp mode under heavy soot loading.
The fixClean/service the DPF or delete with tuning for off-road applications.
05
Radiator coolant leaks
Coolant loss and overheating from the primary or secondary radiator.
The fixReplace the leaking radiator and pressure-test the cooling system.
06
Death wobble / front-end wear
Violent steering shake after hitting a bump, from a worn track bar and steering joints.
The fixReplace the track bar, ball joints, and steering components; align the front end.
07
EGR cooler & valve clogging
Codes, rough running, and coolant loss as the EGR cooler soots up or cracks.
The fixClean or replace the EGR cooler and valve (or delete for off-road).
08
Injector failure
Misfire, smoke, and fuel knock from worn high-pressure injectors.
The fixTest and replace failed injectors with quality units.
09
Glow plug & cold-start faults
Hard cold starts and rough warm-up from failed glow plugs or controller.
The fixReplace failed glow plugs and verify the controller operation.
10
Turbo oil leaks & coolant intrusion
Smoke, oil consumption, or coolant in the oil from seal and gasket failures.
The fixReseal or rebuild the turbo and address failed gaskets early.
Most-requested upgrades
Top 10 upgrades owners do to the 6.7L Power Stroke
The modifications that add reliability and power. We install every one of these in the shop.
01
CP4 bypass kit / CP3 conversion
The single most important upgrade — prevents catastrophic fuel-system failure.
02
Custom tuning
Adds big power and torque and improves drivability and economy.
03
EGR / DPF / DEF delete
Removes the failure-prone emissions hardware (off-road use only).
04
Upgraded turbo
Stronger charger for more air and reliable boost on built trucks.
05
Lift pump / fuel system
Supplies and filters fuel to protect the injection system.
06
Full gauge package
Monitor EGT, boost, fuel pressure, and trans temp under load.
07
4" exhaust & intake
Lowers EGTs and lets the 6.7 breathe for cooler power.
08
Track bar & front-end upgrade
Cures and prevents the dreaded Super Duty death wobble.
09
Built TorqShift transmission
Holds the added torque from tuning without slipping.
10
Upgraded intercooler / CAC
Cooler, denser air for more consistent power and lower EGTs.
Got one of these on your 6.7L Power Stroke?
Call the shop for a real diagnosis, or shop the O-Ringless parts and upgrades we install on our own builds.