2015 Ford F-550 Super Duty Chassis Cab

Reliability tier: verified - see /disclosure/

Engine: 6.7L (Power Stroke, 6.7L)

gen1 - 300hp/660lb-ft - flat detuned calibration across gen1; not verified whether chassis-cab hardware also changed at the 2015 pickup GT32->GT37 turbo update (not yet checked in the parts catalog)

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 (22)

• 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
• 6.7L Power Stroke Diesel Particulate Filter, Chassis Cab (to 11/18/2019)
• DPF Differential Pressure Sensor
• DPF Differential Pressure Sensor (current service PN BC3Z-9J460-G)
• 6.7L Power Stroke EGR Cooler (Heat Exchanger), gen1/gen2
• 6.7L Power Stroke EGR Valve, Chassis Cab (Narrow Frame), 2015 to mid-2016 production - Service Kit
• 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 Fuel Injection Kit, Chassis Cab/gen1-shared (Narrow Frame), Cylinders 1/2/7/8
• 6.7L Power Stroke Fuel Injection Kit, Chassis Cab/gen1-shared (Narrow Frame), Cylinders 3/4/5/6
• 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 Turbocharger Pedestal Gasket
• 6.7L Power Stroke Turbocharger Assembly, gen2 Chassis Cab (detuned)
• 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

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