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ATS Diesel Performance for FORD Powerstroke

trucks. Known for their formidable strength, resilience, and cutting-edge technology, Powerstroke engines are a breed apart. That's why our Ford Powerstroke page is dedicated to providing you with the most advanced, reliable, and high-quality diesel performance solutions available. Whether your goals include towing with confidence, enhancing fuel efficiency, or achieving superior performance, we're here to help you unlock the full potential of your Powerstroke engine.

Our selection of performance parts and services for Ford Powerstroke engines is second to none. We offer an extensive range of turbochargers, transmission enhancements, exhaust systems, custom tuning services, and fuel system upgrades, all designed to elevate your truck's performance to new heights. Our products are engineered with precision, focusing on significant improvements in power, efficiency, and reliability, ensuring your Powerstroke stands ready to tackle any challenge.

ATS Diesel | Aurora VFR Turbochargers

TURBOS

ATS Diesel | Aurora Plus Series Turbochargers

TRANSMISSIONS

ATS Diesel | Aurora Compound Turbochargers

TORQUE CONVERTERS

ATS Diesel | Aurora Single Turbochargers

MANIFOLDS

ATS Diesel | Electronic Fuel Regulators

ELECTRONICS

ATS Diesel | Billet Flex Plates

FLEXPLATES

ATS Diesel | Valve Bodies

VALVE BODIES

ATS Diesel | Transmission Components

TRANSMISSION COMPONENTS

1994-1997 7.3L
1999-2003 7.3L
2003-2007 6.0
2008-2010 6.4L
2011-2014 6.7L
2015-2019 6.7L
2020-2024 6.7L

1994-1997 7.3L POWERSTROKE

The 1994–1997 Ford 7.3L Powerstroke diesel engine is known for its reliability and durability but has several common issues. Hard cold starts often occur due to worn valve seats or leaky injector o-rings, leading to a loss of oil pressure in the HEUI injectors. Overheating is usually caused by thermostat or water pump problems. Fuel filter clogs and diesel fuel heater issues can affect performance. The exhaust back pressure valve (EBPV) may stick closed, causing further performance problems. Head gasket failures often result from insufficient clamping force from head bolts, and cylinder head cracking, which can usually be repaired at a machine shop, is another concern.

1999-2003 7.3L POWERSTROKE

The 7.3 Powerstroke diesel engine, produced between 1994 and 2003, is generally reliable and can last hundreds of thousands of miles with proper maintenance. However, as it ages, it may face several issues. These include overheating problems related to the thermostat and water pump, fuel filter clogs, and diesel fuel heater issues. Additionally, the exhaust back pressure valve (EBPV) may stick closed, and there can be failures in the powertrain control module (PCM) and injector drive module (IDM). The camshaft position sensor (CMP) is also prone to failure. Other common problems include rust and valve cover gasket set failures, which can lead to leaking oil, burning smells, and engine misfires.

2003-2007 6.0 POWERSTROKE

The Ford 6.0L Powerstroke diesel engine (2003-2007) has several common issues. The EGR valve often sticks due to soot buildup or poor fuel quality, affecting engine performance. Blown head gaskets are frequent, caused by stretched head bolts. The oil cooler can clog, leading to EGR cooler failure if it runs out of coolant. Glow plug faults and hard starting are common but can be mitigated with Motorcraft glow plugs. Turbocharger components are prone to failure, though aftermarket up pipe upgrades help. Lastly, exhaust gas temperature (EGT) sensors often fail, with Ford extending their warranty to address this.

2008-2010 6.4L POWERSTROKE

The 2008-2010 6.4L Ford Power Stroke diesel engines have five common issues: leaking radiators, poor fuel mileage, fuel mixing with oil, cracked pistons, and exhaust leaks. Leaking radiators are best fixed with aftermarket aluminum pieces and a core-support brace. Improving intake airflow and adding an aftermarket lift pump can help with fuel mileage. Regular oil checks and maintenance every 4,000-5,000 miles are needed to prevent engine damage from fuel mixing with oil. Cracked pistons require replacing all eight with aftermarket options. Exhaust leaks, often from cracked up-pipes, need full replacement with aluminized hardware.

2011-2014 6.7L POWERSTROKE

The first generation of the Ford 6.7-liter Power Stroke diesel engine (2011–2014) is known for having the most problems, although some issues can affect engines across generations. Common problems include injection pump failure due to metal-on-metal contact in the Bosch CP4.2 pump, turbocharger challenges from ceramic ball bearings in the 2011 and 2012 models, EGR cooler issues from severe soot buildup, NOx sensor failures that cause the ECM to put the truck into "Limp Mode," radiator coolant leaks on the driver's side, and valve seats breaking off in early 2011 production engines, which can cause significant internal damage.

2015-2019 6.7L POWERSTROKE

The 2015–2019 6.7 Powerstroke has several common problems, including a failing EGR cooler that can cause engine overheating or white smoke from the exhaust, potentially leading to serious engine damage. The exhaust gas sensor (EGT) can also fail, with all four sensors in the 6.7L Powerstroke being susceptible to failure, even after replacement. The Bosch CP4.2 injection pump in pre-2020 engines can break down due to metal-on-metal contact caused by air in the pump. A failing high-pressure fuel pump can result in low power output, sudden engine stopping, and inconsistent acceleration. Additionally, the updated turbo in these models, while creating more power and torque, can sometimes lead to issues.

2020-2024 6.7L POWERSTROKE

The third-generation 6.7L Power Stroke diesel engine in Ford's 2020-2024 Super Duty trucks is powerful but has several common issues. The EGR system often suffers from soot buildup, leading to overheating and rough idling. Turbocharger problems like oil starvation and bearing wear cause turbo lag and failures. The fuel system faces high-pressure injector failures and potential catastrophic damage from the CP4 fuel pump. Emissions systems, including the DPF and SCR, frequently clog or malfunction. Cooling system concerns, such as radiator leaks and hose failures, can lead to overheating. The 10-speed transmission has issues with hard shifting and slipping, while electrical problems, including faulty sensors and wiring harness issues, cause intermittent malfunctions.

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