2009 Ford F-250 Super Duty

Reliability tier: verified - see /disclosure/

Engine: 6.4L (Power Stroke, 6.4L)

compound sequential VGT (low+high), DPF from factory, piezo common-rail, ULSD-only - uniform across the run

Applicable failure modes (9)

• DPF clogging / regeneration problems
• EGR cooler failure -> #8 hydrolock
• Front-cover pump cavitation erosion (coolant into oil)
• Head cracking under advanced-timing tunes
• High-pressure pump (Siemens K16) destruction
• Piston ring failure #7/#8 (regen fuel wash)
• Rocker arm tip wear
• Compound turbo bearing-seal leaks
• Valve guide wear (no bronze sleeves)

Applicable parts (30)

• 6.4L Power Stroke Fuel Contamination Repair Kit, 2008-2010 (XDP)
• 6.4L Power Stroke Ford Specification Gold HOAT Coolant (6.4L Power Stroke)
• 6.4L Power Stroke O-Ringed Cylinder Head, loaded (Powerstroke Products)
• 6.4L Power Stroke 6.4L Cylinder Head Service (valve guides, machine work)
• 6.4L Power Stroke Degas Bottle Cap (OEM)
• 6.4L Power Stroke Diesel Particulate Filter (OEM)
• 6.4L Power Stroke 6.4L DPF Cleaning Service (editorial)
• 6.4L Power Stroke DPF Pressure Sensor (OEM)
• 6.4L Power Stroke EGR Cooler (OEM)
• 6.4L Power Stroke EGR Cooler, second unit (OEM)
• 6.4L Power Stroke EGR Valve (OEM)
• 6.4L Power Stroke Long Block (built, stock-OE spec)
• 6.4L Power Stroke Engine Oil, CK-4 15W-40 (6.4L Power Stroke spec)
• 6.4L Power Stroke Exhaust Manifold Gasket (OEM)
• 6.4L Power Stroke Fan Clutch (OEM, severe-duty)
• 6.4L Power Stroke Fuel Filter Element (OEM)
• 6.4L Power Stroke 6.4L Fuel System Flush / Cleaning (post-K16 failure)
• 6.4L Power Stroke Glow Plug (OEM)
• 6.4L Power Stroke Glow Plug Relay / Control Module (OEM)
• 6.4L Power Stroke Head Gasket Set (OEM)
• 6.4L Power Stroke 6.4L Power Stroke Head Stud Kit (ARP 2000)
• 6.4L Power Stroke High-Pressure Fuel Pump (Siemens K16), Ford reman
• 6.4L Power Stroke 6.4L HPFP Upgrade Paths (editorial)
• 6.4L Power Stroke Fuel Injector (Siemens piezo), Ford reman
• 6.4L Power Stroke Oil Cooler (OEM)
• 6.4L Power Stroke Radiator (OEM)
• 6.4L Power Stroke 6.4L Power Stroke Rocker Arm / Valve Cover Sets (OEM style)
• 6.4L Power Stroke Thermostat (OEM)
• 6.4L Power Stroke Compound Turbocharger, Ford reman
• 6.4L Power Stroke Water Pump (OEM)

Platform recipes (3)

• The 6.4 reliability package (modes fm-64-head-cracking-tunes / fm-64-piston-ring-failure / plus cooling discipline): stock the truck against its two tuning-adjacent killers - head cracking on advanced-timing tunes and #7/#8 ring scuffing from regen fuel wash
• Emissions-side repair (modes fm-64-egr-cooler-hydrolock / fm-64-dpf-clog): the 6.4 has TWO EGR coolers (primary 9P456-C and secondary 9F464-F) - both are suspects in coolant-loss/hydrolock, and the hydrolock path feeds cylinder #8 at shutdown
• The K16 high-pressure pump event (mode fm-64-hpfp-destruction): the 6.4's signature catastrophic failure

Reference for this truck