Which Ford 6.7 Power Stroke Years Have the Most Problems?
If you’re eyeing a Ford Super Duty with the 6.7 Power Stroke diesel, you’ve probably heard the engine is a workhorse—when it’s running right. But not every model year is created equal. Some years have earned a reputation among owners and diesel techs for being, well, a bit more temperamental. So, which 6.7 Power Stroke years should you approach with caution?
What Went Wrong with the Early 6.7 Power Stroke Engines?
Let’s rewind to 2011, the debut year for the 6.7-liter Power Stroke. Ford was breaking new ground, moving away from the troubled 6.4, but the first batch of 6.7s had some teething issues. The most notorious? Turbocharger failures. Owners reported sudden loss of power, odd noises, and expensive repair bills—often before hitting 100,000 miles.
The culprit was a single-sequential turbo design that just couldn’t handle the heat and stress. Combine that with early exhaust gas recirculation (EGR) cooler problems and you had a recipe for frustration. According to a 2022 survey by Diesel Tech Magazine, nearly 18% of 2011-2012 owners reported at least one major turbo or EGR-related failure in the first five years.
Are 2012 and 2013 Models Any Better?
Ford made some tweaks for 2012 and 2013, but many of the same issues lingered. The turbo design was revised, but reliability didn’t jump overnight. Fuel system problems—especially with the CP4.2 high-pressure fuel pump—started cropping up. When these pumps fail, they can send metal shavings through the entire fuel system, leading to repairs that can easily top $8,000.
Anecdotally, diesel forums are filled with stories of 2012-2014 owners dealing with injector issues, hard starts, and check engine lights. While not every truck from these years is a lemon, the odds of a major repair are higher than you’d like.
Did Ford Fix the Problems in Later Years?
By 2015, Ford had clearly listened to the feedback. The turbo was swapped for a simpler, more robust design. The EGR system was improved, and software updates addressed some of the nagging drivability quirks. Reliability scores from J.D. Power and Consumer Reports both ticked upward for 2015-2016 models, and owner complaints dropped by nearly 30% compared to the first-gen trucks.
That said, no engine is bulletproof. Even post-2015 6.7s can suffer from EGR clogging, DEF system glitches, and the occasional fuel system hiccup. But the frequency and severity of these issues are much lower, making these years a safer bet for buyers.
How Do Real Owners Feel About the Worst Years?
If you want the unfiltered truth, talk to folks who’ve lived with these trucks day in and day out. On platforms like PowerStroke.org and the Ford Truck Enthusiasts forum, you’ll find threads with thousands of posts dissecting every rattle and warning light.
A recurring theme: 2011-2014 trucks are often described as “great when they run, but expensive when they don’t.” Many owners who’ve had major failures swear by extended warranties or recommend buying newer models. On the flip side, some report trouble-free ownership with diligent maintenance—oil changes, quality fuel, and regular inspections go a long way.
What Should You Look Out for When Shopping Used?
If you’re set on a used 6.7 Power Stroke, a little homework pays off. Ask for service records. Look for evidence of regular oil and fuel filter changes. If the truck is a 2011-2014, check if the turbo or fuel system has already been replaced—this could save you thousands down the road.
It’s also smart to have a trusted diesel mechanic inspect the truck before you buy. They’ll spot red flags like injector balance rates, turbo shaft play, or signs of fuel contamination that might not show up on a quick test drive.
Is the 6.7 Power Stroke Still Worth It?
Despite the rocky start, the 6.7 Power Stroke has matured into one of the most respected diesel engines in the heavy-duty market. Towing capacity, torque, and fuel efficiency are all strong points, especially in later models. For many owners, the peace of mind that comes with a post-2015 truck is worth the premium.
The big takeaway? Avoiding the riskiest years isn’t about perfection—it’s about smarter adjustments. Start with one change this week—maybe digging into service records or scheduling a pre-purchase inspection—and you’ll likely spot the difference by month’s end.
