2011–2019 FORD SUPER DUTY · 6.7L POWER STROKE
2011–2019 6.7 Power Stroke repair in Tucson: weak points & fixes.
Ford’s own 6.7 is a strong, quiet diesel with a tough block. Its weak spots are the CP4 fuel pump, early turbos, the cooling system and emissions sensors. Here’s what we see on these trucks and how we fix it at your location.
- 390–450 hp735–935 lb-ft stock
- Bosch CP4.2common rail · DPF · DEF
- 6R1406-speed automatic
- We come to youTucson & nearby
Jump to a system
KNOW YOUR TRUCK
Gen 1 or Gen 2? It changes the fix.
Ford changed the turbo, injectors and ratings in 2015. Your year tells us what to check first.
Gen 1
- 390 hp / 735 lb-ft at launch, then 400 / 800
- Garrett DualBoost turbo with ceramic bearings (early failures)
- Early coolant leak at the turbo coolant pipe (2011–2012)
- CP4.2 injection pump
Gen 2
- 440 hp / 860 lb-ft (2015–16), up to 450 / 935 (2018–19)
- Larger, more reliable turbo
- Higher-flow injectors
- Still the CP4.2 injection pump
POWER THROUGH THE YEARS
Where the 2011–2019 6.7 Power Stroke fits in Power Stroke history.
Peak factory pickup ratings by generation, horsepower and torque. Yours is highlighted. Tap any bar to see that generation.
- Horsepower
- Torque (lb-ft)
WEAK POINTS, SYSTEM BY SYSTEM
What fails on the 2011–2019 6.7 Power Stroke, and how we fix it.
Tap a system to see what fails, what you’ll notice and how we fix it. Common = we see it often. Towing / tuned = shows up with heavy loads or added power. High miles = age and wear items.
CP4 pump & fuel system
CP4.2 injection pump failureCommon
You’ll notice: hard starts, stalling, no start, fuel pressure codes. Sometimes no warning at all.
Why: The CP4.2 relies on diesel fuel for lubrication. Water, air or poor fuel can wear it until it sends metal through the whole fuel system.
Our fix: We protect it with clean fuel and a FASS system, and offer the S&S CP4-to-DCR conversion. If it has already failed, we replace every part the metal reached. CP4-to-DCR guide →
Water in the fuelCommon
You’ll notice: water-in-fuel light, rough running.
Why: Water is the CP4’s worst enemy.
Our fix: We drain the separator, replace filters and fix the source.
Turbo & air
Turbo failure (2011–2014)Common
You’ll notice: loud whine, loss of power, smoke, limp mode.
Why: The first-generation turbo used ceramic ball bearings that failed early on many 2011–2012 trucks.
Our fix: We replace it with an updated turbo and check for damage downstream.
Boost leaksHigh miles
You’ll notice: low power, a whistle, black smoke.
Why: Intercooler pipes and boots loosen and split with heat and age.
Our fix: We pressure-test the intake side and replace leaking parts.
Cooling
Radiator and coolant leaksCommonTowing / tuned
You’ll notice: coolant loss, sweet smell, running hot towing in summer.
Why: The 6.7 runs two cooling loops with two radiators, and the early trucks had leak-prone radiators and coolant pipes.
Our fix: We pressure-test both loops and replace leaking parts, including XDP X-Tra Cool radiators on 2011–2016 trucks.
EGR, DPF, DEF & sensors
EGR cooler cloggingCommon
You’ll notice: EGR codes, power loss, coolant loss in some cases.
Why: Soot builds up, especially with lots of idling.
Our fix: We clean or replace the cooler and fix what’s making extra soot.
NOx, EGT sensors and DEF heatersCommon
You’ll notice: check engine light, reduced power warnings, DEF messages.
Why: These sensors live in a lot of heat and fail with age, and early trucks were especially prone.
Our fix: We test and replace the failed part and clear the system, keeping it emissions legal.
Clogged DPFHigh miles
You’ll notice: frequent regens, reduced power.
Why: Short trips and idling stop the filter from cleaning itself.
Our fix: We find the cause and clean or replace the filter.
Engine
Glow plugs and injector sealsHigh miles
You’ll notice: hard cold starts, fuel smell, rising oil level.
Why: Glow plugs wear out, and leaking injector seals can add fuel to the oil.
Our fix: We replace failed glow plugs and reseal injectors as needed.
6R140 automatic
Shift problems and heatTowing / tunedHigh miles
You’ll notice: harsh or late shifts, high transmission temps when towing.
Why: Heat and old fluid are hard on any automatic.
Our fix: We service it with the right fluid, add a deeper pan, and repair or replace the unit when needed.
Front end & steering
Loose steering and death wobbleHigh miles
You’ll notice: wandering, play in the wheel, a shake after a bump.
Why: Heavy engines wear out ball joints, tie rods and track bar bushings.
Our fix: We rebuild the front end with heavy-duty parts and set the alignment.
RELIABILITY UPGRADES
Bulletproof it in the right order.
If you plan to keep your 6.7, these are the upgrades we recommend, in the order that protects it best.
- CP4 protectionClean fuel plus the S&S CP4-to-DCR conversion is the best protection against the 6.7’s most expensive failure.Call nowRequest a quote
- FASS fuel systemExtra filtration and water separation that feeds the factory pump.Call nowRequest a quote
- Fuel filters on timeChanging filters and draining water often matters more on this engine than almost any other.Call nowRequest a quote
- Cooling systemHealthy radiators and coolant keep the 6.7 alive in Tucson heat.Call nowRequest a quote
- GaugesFuel pressure, coolant and transmission temps on a monitor warn you early.Call nowRequest a quote
- Transmission and axle coolingA deeper 6R140 pan and a Banks Ram-Air rear cover keep fluids cooler when towing.Call nowRequest a quote
MAINTENANCE SCHEDULE
2011–2019 6.7 Power Stroke service intervals.
These are Ford’s factory intervals from the owner’s manual schedule. The factory “severe” column covers towing, dusty roads, short trips and long idling, which describes most working trucks in Southern Arizona. Our recommendation follows the severe schedule, with oil every 5,000 miles and fuel filters every 10,000.
| Service | Factory, normal use | Factory, severe use | Our recommendation |
|---|---|---|---|
| Engine oil & filter | 10,000 mi or oil life monitor | 5,000 mi or oil life monitor | Every 5,000 mi |
| Fuel filters (both) | 22,500 mi or dash message | 15,000 mi / 6 months / 600 hours | Every 10,000 mi |
| Engine air filter & pre-filter | 45,000 mi | Inspect at every oil change | Inspect at every oil change |
| Coolant (both loops) | 105,000 mi / 6 years first, then 45,000 mi / 36 months | 60,000 mi first, then 45,000 mi / 36 months | 60,000 mi first, then 45,000 mi / 36 months |
| Crankcase vent (CCV) separator | About 100,000 mi on some trucks | — | About 100,000 mi on some trucks |
| 6R140 fluid & filter | 150,000 mi | 50,000 mi | 50,000 mi |
| Transfer case fluid | 150,000 mi | 60,000 mi | 60,000 mi |
| Front axle fluid | 150,000 mi | 50,000 mi | 50,000 mi |
| Rear axle fluid | 100,000 mi | 50,000 mi | 50,000 mi |
Always go by your owner’s manual for your exact truck. Factory figures are maximums, and the dash service reminder comes first when it shows sooner.
WANT MORE POWER?
2011–2019 6.7 Power Stroke performance upgrades.
Staged builds, lift pumps, transmission, exhaust and suspension upgrades for the 2011–2019 6.7 Power Stroke.
BUYING A 2011–2019 6.7 POWER STROKE?
Get it inspected before you buy.
Our Diesel Pre-Purchase Inspection checks the engine, fuel system, transmission and front end, and looks for signs of past problems. We meet you at the seller.
How mobile service worksTell us your truck and where it is, we diagnose on site, you approve a written estimate, and we fix it where it sits.
See how it works →PLAIN-ENGLISH GLOSSARY
2011–2019 6.7 Power Stroke terms, explained.
- CP4.2
- The Bosch high-pressure fuel pump on 2011–2019 6.7s. Sensitive to water and poor fuel.
- DCR conversion
- Replaces the CP4 with a more robust pump design from S&S.
- DEF
- Diesel exhaust fluid. Sprayed into the exhaust to cut emissions.
- NOx sensor
- Measures emissions in the exhaust. A common failure on early 6.7s.
- DPF
- Diesel particulate filter. Traps soot and burns it off during a regen.
- Secondary cooling loop
- The 6.7’s second radiator circuit for the charge air, transmission and fuel coolers.
- 6R140
- Ford’s six-speed automatic behind the 2011–2019 6.7.
- CARB EO
- A California Air Resources Board Executive Order number. It means a part is legal for street use in all 50 states.
Name-brand partsWe install proven brands like Banks, Edge, FASS, S&S Diesel, PPE, aFe, XDP and Bilstein.
See all the brands we install →OWNER QUESTIONS
2011–2019 6.7 Power Stroke questions, answered.
Is the 2011–2019 6.7 Power Stroke reliable?
Yes, especially 2015–2019. The big risk is the CP4 fuel pump, so fuel filter service and protection matter. Early 2011–2014 trucks also had more turbo and sensor trouble.
What is the CP4 problem?
The CP4.2 high-pressure pump can wear out and send metal through the fuel system, which is very expensive to fix. We explain the protection options on our CP4-to-DCR page.
Do you delete emissions equipment?
No. We repair and upgrade with emissions-legal parts only.
Why don’t you list prices for these repairs?
Every truck is different. Mileage, past repairs and how it’s used all change the parts and labor. Call us at 520-990-1033 and we’ll quote your truck.
What warranty do repairs have?
Repair labor is backed for 1 year or 12,000 miles, and new parts carry their manufacturer’s warranty. Warranty details →
LET’S TALK ABOUT YOUR TRUCK
Call, text or request a quote.
Tell us your year, mileage and what you want done. We’ll recommend the right repair, quote it and come to you.