2024 Ford F-450 Super Duty Chassis Cab

Reliability tier: verified - see /disclosure/

Engine: 6.7L (Power Stroke, 6.7L)

gen3 - 330hp/825-950lb-ft (825 2020-2022, 950 2023+ per Wikipedia: Ford Super Duty) - no High-Output option on chassis cab

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 (12)

• 6.7L Power Stroke EGR Cooler Upgrade with H-Core Technology, 2011-2024 (Bullet Proof Diesel)
• ford-powerstroke-6_7: coolant-hose (honest catalog gap)
• 6.7L Power Stroke CP4.2 High-Pressure Fuel Injection Pump, 2023-2026
• 6.7L Power Stroke Diesel Particulate Filter, Chassis Cab (from 11/18/2019)
• 6.7L Power Stroke Injector, gen3 (2023-2025), Left bank, Cylinders 5/6
• 6.7L Power Stroke Injector, gen3 (2023-2025), Left bank, Cylinders 6/8
• 6.7L Power Stroke Injector, gen3 (2023-2025), Right bank, Cylinders 1/2
• 6.7L Power Stroke Injector, gen3 (2023-2025), Right bank, Cylinders 3/4
• 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 Assembly, standard (non-HO), 2023-2026

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

Reference for this truck