2015 Ford F-450 Super Duty

Reliability tier: verified - see /disclosure/

Engine: 6.7L (Power Stroke, 6.7L)

gen2 - 440hp/860lb-ft - Garrett GT37 journal-bearing turbo replaces the ceramic-bearing GT32 (hardware change, not just recalibration), refined injectors

Applicable failure modes (11)

• Dual-circuit cooling system leaks (radiator / crossover tube / degas bottle / water pump)
• CP4.2 high-pressure fuel pump contamination cascade
• DEF / SCR / NOx sensor faults
• DPF clogging / regeneration problems
• EGR cooler thermal-fatigue coolant leak
• EGR valve soot clogging / sticking
• Low-pressure fuel supply weakness (lift pump, filters, water-in-fuel)
• Glow plug wear and cold-start faults, plus an isolated 2011-2013 tip-separation defect
• Piezo injector wear and fuel dilution of engine oil
• Intercooler condensation ingestion + cold-side charge-pipe fatigue
• VGT turbocharger failure - generation dependent (ceramic-bearing GT32 vs journal-bearing GT37+)

Applicable parts (43)

• Banks Power Boost Tube System, hot and cold side (2011-2016 6.7L Power Stroke)
• 6.7L Power Stroke EGR Cooler Upgrade with H-Core Technology, 2011-2024 (Bullet Proof Diesel)
• 6.7L Power Stroke Coolant Crossover Tube (Ford BC3Z-8C471-A, 2011-2016)
• ford-powerstroke-6_7: coolant-hose (honest catalog gap)
• 6.7L Power Stroke CP4.2 High-Pressure Fuel Injection Pump
• DEF (Diesel Exhaust Fluid) Injector
• DEF (Diesel Exhaust Fluid) Injector (current service PN AL3Z-5J281-B)
• Coolant Recovery (Degas Bottle) Cap, gen1/gen2
• DPF Differential Pressure Sensor
• DPF Differential Pressure Sensor (current service PN BC3Z-9J460-G)
• 6.7L Power Stroke EGR Cooler (Heat Exchanger), gen1/gen2
• EGR Cooler Seal Kit
• EGR Cooler Seal Kit (current service PN BC3Z-9P455-B)
• 6.7L Power Stroke EGR Valve, Pickup (Wide Frame), 2015 to mid-2016 production
• Exhaust Gas Temperature (EGT) Sensor, single
• 6.7L Power Stroke Fuel Contamination Repair Kit, 2011-2022 (XDP / Alliant Power)
• 6.7L Power Stroke Fuel Filter Element (Ford BC3Z-9N184-B, 2011-2016)
• 6.7L Power Stroke Billet Fuel Filter Housing / Leak Prevention Kit (S&S Diesel Motorsport)
• 6.7L Power Stroke Glow Plug
• Glow Plug Control Module (gen2)
• 6.7L Power Stroke Fuel Injection Kit, Pickup (Wide Frame), 2015-2019, Cylinders 1/2/7/8
• 6.7L Power Stroke Fuel Injection Kit, Pickup (Wide Frame), 2015-2019, Cylinders 3/4/5/6
• 6.7L Power Stroke Charge Air Cooler (Intercooler) Assembly
• 6.7L Power Stroke In-Tank Low-Pressure Lift Pump
• NOx Sensor, Upstream/Front
• NOx Sensor, Upstream/Front (current service PN DC3Z-9D378-D)
• NOx Sensor, Downstream/Rear
• NOx Sensor, Downstream/Rear (current service PN DC3Z-9D378-C)
• 6.7L Power Stroke Secondary Radiator (Front position)
• 6.7L Power Stroke Secondary Radiator (Front position) (current service PN BC3Z-8005-M)
• 6.7L Power Stroke Main Radiator (Rear position)
• 6.7L Power Stroke Main Radiator (Rear position) (current service PN BC3Z-8005-K)
• 6.7L Power Stroke CP4-to-DCR Pump Conversion (S&S Diesel Motorsport)
• 6.7L Power Stroke CP4 Disaster Prevention Bypass Kit, Gen2.1 (S&S Diesel Motorsport)
• 6.7L Power Stroke LPK/DPK Replacement Filter Kit (S&S Diesel Motorsport)
• 6.7L Power Stroke Thermostat, Driver Side
• 6.7L Power Stroke Thermostat, Passenger Side
• 6.7L Power Stroke Turbocharger Pedestal Gasket
• 6.7L Power Stroke Auxiliary Water Pump, Dual Alternators
• 6.7L Power Stroke Auxiliary Water Pump, Single Alternator
• 6.7L Power Stroke Primary (Engine) Water Pump, gen1/gen2
• 6.7L Power Stroke Main Radiator, XDP X-TRA Cool XD291 (2011-2016)
• 6.7L Power Stroke Secondary Radiator, XDP X-TRA Cool XD299 (2011-2016)

Platform recipes (5)

• Aftertreatment repair for the 2011-2022 6.7 (modes fm-ps67-def-system / fm-ps67-dpf-clog): sensors lie first - verify the DPS and EGT sensors before any assembly spend
• Full repair path after a confirmed CP4.2 high-pressure pump contamination event (fm-ps67-cp4-fuel-pump): metal debris in the fuel filter means the pump, injectors, rails, and lines are all contaminated, not just the pump
• Preventive measures against the CP4.2 contamination cascade (fm-ps67-cp4-fuel-pump) and the separately-documented plastic fuel-filter-housing cracking issue (fm-ps67-fuel-delivery) - cheap insurance against the platform's single costliest failure mode, applicable across all three generations since the CP4.2 pump has been used throughout (an aftermarket parts maker's 6.7L Power Stroke guide, a parts retailer's 6.7L Power Stroke guide)
• EGR repair by generation (modes fm-ps67-egr-valve / fm-ps67-egr-cooler): the 6.7's EGR hardware is generation- AND frame-split
• Turbocharger repair for fm-ps67-vgt-turbo - and the platform's clearest illustration of why generation matters: gen1 (2011-2014, Garrett GT32 ceramic-bearing) and gen3 (2020-22, per Ford's own catalog note) use ENTIRELY DIFFERENT turbocharger assembly part numbers (BC3Z-6K682-A/C vs LC3Z-6K682-A) - ordering the wrong one is not a simple supersession mistake, it is the wrong physical part

Recalls that include this truck (1)

• 14V-204 (April 17, 2014) - POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM): Ford Motor Company (Ford) is recalling certain model year 2015 F-250, F-350, F-450, and F-550 Super Duty trucks manufactured September 13, 2013, through March 28, 2014, and equipped with 6.2L gasoline or 6.7L diesel...

Matched by the model and model year NHTSA lists for each recall - a recall often covers only part of a year's production, so read its text for the build dates and versions it names. Whether a recall is still open on your VIN is not known here; check nhtsa.gov/recalls. All recalls, investigations and bulletins for this engine: /recalls/ford-powerstroke-6_7/

Reference for this truck