How long will a Ford 6.4 diesel last?
In typical ownership, a Ford 6.4L Power Stroke can run for about 250,000 to 350,000 miles with proper maintenance, and some trucks push past 400,000 miles with proactive care. The exact lifespan depends on how well the engine and its emissions system are maintained and how aggressively the truck is used for towing or heavy workloads.
Context: the 6.4L Power Stroke at a glance
The 6.4-liter Power Stroke was produced for Ford Super Duty trucks from 2007 to 2010. Built by Navistar, it introduced a high-pressure common-rail fuel system and a diesel particulate filter (DPF) to meet emissions regulations. While powerful, the engine has a reputation for costly failures if routine maintenance is neglected, particularly around cooling and emissions components.
Real-world lifespans
Owners report a wide range of outcomes based on maintenance history and usage patterns. The following ranges reflect common experiences in the field.
- Average, well-maintained examples commonly reach around 250,000–350,000 miles.
- With proactive maintenance and timely replacement of known weak points, 400,000 miles or more is achievable.
- Without consistent upkeep or after major failures, engines may fail well before 200,000 miles.
In practice, the engine’s longevity hinges on keeping cooling and emissions systems in good repair and avoiding prolonged overheating or neglecting early warning signs.
Common failure points to monitor
Focusing on the 6.4’s most frequently problematic areas can help prevent extendable life and avoid expensive repairs.
- EGR cooler failures and leaks
- Oil cooler leaks and wear in the high-pressure oil system
- Turbos and variable vane actuators
- High-pressure oil pump (PHFP) and related injector wear
- Fuel injectors and the FICM (fuel injector control module) reliability
- DPF soot management and exhaust cooling system
Addressing these issues early—especially EGR/oil cooler problems and DPF maintenance—can prevent cascading failures that shorten engine life.
Maintenance and preventive care that matter most
Routine, rigorous upkeep is widely regarded as the best predictor of long life for the 6.4. Technicians and owners emphasize sticking to recommended service intervals and replacing components before they fail.
- Adhere to the manufacturer’s maintenance schedule for oil changes, using high-quality synthetic oil and filters at recommended intervals.
- Maintain the cooling system vigilantly to prevent overheating, and fix leaks promptly.
- Monitor and service the EGR/DPF system; replace EGR coolers as needed and ensure DPF regenerations occur properly.
- Consider proactive replacement of the oil cooler and associated seals at suggested intervals to avoid oil-coolant mixing.
- Inspect the fuel system, including injectors and the FICM, and address symptoms early rather than later.
- Keep all fluids and drivetrain components in good condition to reduce engine stress during heavy-duty use.
Following a disciplined maintenance plan can significantly improve the likelihood of reaching higher mileages and preserving overall engine health.
Buying used: what to check for remaining life
When shopping for a used 6.4-powered Super Duty, buyers should look for a documented maintenance history and evidence that major weak points have been addressed.
- Service records showing regular oil changes and cooling-system work
- History of EGR cooler or oil cooler replacements and other cooling system maintenance
- DPF status and documented regens or cleaning history
- FICM and injector replacement history and current performance indicators
- Overall condition of the turbo, hoses, and exhaust system
A truck with comprehensive service records and recent major component work is typically a stronger bet for longer remaining life than one with spotty maintenance.
Summary
The Ford 6.4 diesel can deliver substantial longevity when properly cared for, with many examples lasting well into the 250,000–350,000 mile range and some surpassing 400,000 miles with proactive maintenance. Its durability depends on disciplined maintenance, responsible use, and timely replacement of known weak points in the cooling and emissions systems. For prospective buyers, a well-documented service history and evidence of prior repairs to EGR/oil coolers, DPF, and fuel-system components are strong indicators of remaining life.
In short, the 6.4 can be a durable workhorse, but it rewards owners who stay ahead of issues rather than chasing problems after they arise.
