6.4 Powerstroke Life Expectancy (How Reliable is it?)

6.4 powerstroke life expectancy

The 6.4L Power Stroke had a lot to contribute when it was launched in 2007 for the 2008 Ford Super Dutys. Following the five years of 6.0L Power Stroke failures, Ford enthusiasts eagerly anticipated a new, supposedly more dependable engine.

The 6.4L V8’s compound turbocharger setup, common-rail injection system, 350hp, and 650 lb-ft looked fantastic on paper (and it could generate 550 – 600hp with a program). However, it didn’t last long.

How Many Miles Will a 6.4 Power Stroke Last?

You still can’t have it all, even if you’re the world’s largest automaker. Ford has had a decade of substandard diesel pickups in its portfolio after discontinuing the famous 7.3-liter Super Duty engine.

The company now knows better. Reliability is generally an issue for truck enthusiasts. However, the 2008 6.4-liter Power Stroke is the most certain to have an engine rebuild.

The worst part is that it estimates that you will require extensive repairs between 65,000 to 119,000 miles. The 6.4L Power Stroke is plagued with many issues, including faulty emissions control parts, fuel system corrosion,

leaking hoses and radiators, fuel system corrosion, fractured turbo up-pipes, and significant oil dilution. Engine catastrophic failure is common between 150,000 and 200,000 miles in most situations.

For this reason, many 6.4L owners give up on the truck since the repair expenses are so costly (sometimes more than twice what would be for the 6.0L Power Stroke).

How Reliable Is a 6.4 Power Stroke?

What’s the 6.4 Power Stroke’s reliability? The topic is difficult to address. Some argue that the 6.4L diesel is a major upgrade over the preceding 6.0 Powerstroke, while others are less enthusiastic.

Many other Ford diesel owners have had unfortunate experiences with the 6.4, dubbed one of the least reliable engines ever made by Ford. The truth tends to be someplace between the two.

It wasn’t just Ford that developed the 6.4 Power Stroke when emissions equipment was getting increasingly complex. Emissions regulations and the need for extra equipment are to blame for failures, including EGR, D.P.F., oil coolers, and more.

You can improve the Ford 6.4 diesel’s reliability by removing a lot of stuff. Unrelated faults such as cracked pistons, HPFP wiring chafing, and so on are also present with the Powerstroke 6.4.

6.4 Power Stroke reliability is average. However, the 6.4 Power Stroke is unreliable as the 5.9 Cummins and 7.3 Power Stroke. However, it’s no fair comparison anymore with all of the emissions-related stuff.

How Can I Make My 6.4 Power Stroke Last?

The 6.4L Powerstroke has unmatched power. Performance enhancements can boost horsepower and torque to the 6.4L Powerstroke.

You can reach 500 horsepower while maintaining emissions without running out of money. Power and torque aren’t everything. Gas mileage and reliability are essential.

The 6.4L Powerstroke has outstanding performance but poor fuel efficiency and reliability. 6.4L Powerstroke aftermarket components and accessories may make the trucks more reliable and boost horsepower, torque, and fuel efficiency.

I have listed some of the best 6.4L Powerstroke performance upgrades for you.

Digital Performance Monitors & Gauges

A truck monitor and gauge display benefits by providing real-time truck data and analytics.

The D.T.C. will help you identify common problems like reading D.T.C.s (diagnostic trouble codes). 6.4L Powerstroke issues like an oil cooler blockage are difficult to detect. D.T.C. codes can appear or not. However, you can easily identify this problem with the right parameters.

For example, you likely have a blocked oil cooler if you see a large difference between engine coolant and oil temperature.

Systemic Engine Coolant Filtration

Recirculating hot exhaust gases are cooled using the EGR emissions system’s coolant or anti-freeze. The process minimizes the nitrogen oxides produced from the exhaust, while the engine coolant breaks down from the high temperatures. Filters in engine coolant filtering systems collect any particle or breakdown.

As a result, it extends the lifespan of the engine coolant, EGR, oil cooler, and water pump. Tuners & Programmers for the 6.4L Powerstroke

Tuners and programmers

modify engine settings like fuelling to boost performance. You can change the transmission parameters to enhance shift points. Custom tuning will produce the greatest results. Head studs, fuel system upgrades, and beefier transmission upgrades often accompany tunes.

Cold Air Intake

Your 6.4L Powerstroke will improve performance and fuel economy with a cold air intake. They’re also affordable and effortless to install. Cold air intakes are one of the ideal 6.4L Powerstroke performance improvements, particularly for first-time diesel users.

Aftermarket Larger Intercoolers

Diesel trucks benefit from aftermarket intercoolers. Cooler, denser air can boost engine output. In addition, they reduce E.G.T.s and boost gas mileage. So it’s hard not to buy one.

I recommend these aftermarket 6.4L Powerstroke intercoolers; Bank’s Power Techni-Cooler Intercooler, Mishimoto Intercooler Upgrade, and Afe Bladerunner Intercooler.

What Are the Pros and Cons of a 6.4 Power Stroke?


  • Factory bed plate
  • 550 to 600 horsepower with customized tuning
  • Head bolts with a larger diameter prevent head gaskets from rupturing.
  • Connecting rods manufactured by the manufacturer can withstand greater than 900rwhp.
  • Long-term support for 600rwhp is possible with factory compound turbochargers.
  • Most 2008-2010 engines are coupled to an even more durable 5R110 TorqShift automatic transmission than the 6.0L’s transmission.


  • Injector failures can damage pistons.
  • D.P.F.s will always fail.
  • Common EGR cooler failure
  • Pistons deteriorate with age and use
  • Oil dilution is continual owing to emissions regeneration cycles
  • Oil dilution is continual owing to emissions regeneration cycles
  • Radiators have a reputation for leaking.
  • Most significant repairs require the removal of the cab.
  • Contaminants in a high-pressure fuel system can wipe out the entire system



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