Can the 6.4 Powerstroke Be Saved?

I see so many for sale with 200k+ on them. This engine had a short run and is regarded as the worst diesel ever, so why so many of them on the market? Can these be ‘bulletproofed’?

First thing they need is proper machine work performed: updated pistons, a cam, and good lifters. The crankshafts also had some machining errors from the factory. The regeneration process used instead of DEF fluid was hard on cylinder walls and rings, especially on the rear cylinders. A good fuel source and additives to help the K16 injection pump can prolong its life.

@Oli
So they can be saved if you throw money at it?

Rex said:
@Oli
So they can be saved if you throw money at it?

Yes, but you need a skilled machine shop. I built one from the ground up two years ago. It cost a lot, but with billet rods, larger chargers, and high-quality internals, it has held up well.

If you spend 20k, it MAY be salvageable. Totally pointless, though, because you can get a 6.7 Cummins in there for that money and actually add value to the truck.

With the 6.4, you can throw whatever upgrades you want at it, but there’s still a high risk of failure no matter what. Source: 3x 6.4 owner.

Mine’s been great. 210k miles and no issues since adding an aftermarket oil cooler and deleting the DPF. Everybody says they are trash, but that hasn’t been my experience.

Auden said:
Mine’s been great. 210k miles and no issues since adding an aftermarket oil cooler and deleting the DPF. Everybody says they are trash, but that hasn’t been my experience.

That’s the thing about them and the 6.0s. It’s a crap shoot. When you buy a 6.0 or a 6.4, you’re gambling. It might be fine, or it might be $18,000 worth of repairs.

They are, unfortunately, a throwaway engine by design—no wrist pin bushings and no valve guides. It’s a cost-cutting nightmare.

Man, they might be the worst diesel made, but I love the truck they came in so much. I’ve got a Cummins, but I’ve always wanted one despite knowing the risks.

I love my 6.4 6-speed. I don’t care what people say. It’s been a great truck.

Yes, but it takes a LOT of work. If you delete the emissions system, install new pistons, and upgrade critical parts, it can be decent. Just keep in mind that the 6.4 uses a 4-bolt head design like the 6.0, so head lifting can still occur if you push it too hard.

Great trucks. I loved my '08. The 6.4 has fundamental flaws that are not fixable for reasonable prices. A very well-done Cummins swap can solve the problem, but at this point, the newest of these trucks is 14 years old.

Don’t do it! The late great Bill Hewitt will tell you: unless your money is never-ending, avoid it. You’d be better off with a 6.0.

Oh, she can be saved. The same way a stripper who’s been on the pole for 10 years can be saved and made your wife. It’s going to take a lot of money, and you’re going to get hurt a few times.