Powerstroke 6.4L Blew Up
#1
06-11-2013, 10:14 PM
Join Date: Jun 2013
Location: Orange County, CA
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Powerstroke 6.4L Blew Up
I have a 2008 F350 with a 6.4L Powerstroke diesel engine that just experienced total engine failure.
There is a heavy burn star pattern on all 8 pistons, a few pistons are cracked, a few cylander walls are scored, glow plugs are melted, both heads are cracked with multiple stress fractures in each head.
About 1 month previously, the transmission would not work in tow mode and caused the engine to go into limp home mode. The dealership just replaced the entire tranny as a warranty item. About 1 week before the engine failure, I put in a 5.25 oz bottle of Lucas injector cleaner with a full tank of gas.
The Ford dealership is saying that the star pattern on all 8 pistons is due to high pressure fuel overspray and is evidence that I had a tuner on this engine and that the warranty is invalid. I did not have a tuner. Any ideas of what might have caused this engine failure?
Also, they only ripped down the top half of the motor, not the bottom half. I heard this might have been caused by a cracked crank shaft, but Ford refuses to investigate this possibility. Any ideas on how to pursue Ford on this issue?
There is a heavy burn star pattern on all 8 pistons, a few pistons are cracked, a few cylander walls are scored, glow plugs are melted, both heads are cracked with multiple stress fractures in each head.
About 1 month previously, the transmission would not work in tow mode and caused the engine to go into limp home mode. The dealership just replaced the entire tranny as a warranty item. About 1 week before the engine failure, I put in a 5.25 oz bottle of Lucas injector cleaner with a full tank of gas.
The Ford dealership is saying that the star pattern on all 8 pistons is due to high pressure fuel overspray and is evidence that I had a tuner on this engine and that the warranty is invalid. I did not have a tuner. Any ideas of what might have caused this engine failure?
Also, they only ripped down the top half of the motor, not the bottom half. I heard this might have been caused by a cracked crank shaft, but Ford refuses to investigate this possibility. Any ideas on how to pursue Ford on this issue?
#2
06-12-2013, 05:11 AM
#3
06-12-2013, 11:33 AM
Copying my posts from the other thread.
Also - Very unlikely that this has anything to do with Crankshaft related or your fuel additive.
In all probability, this was all aftermarket tuning that caused this.
Originally Posted by AZPatMan
Diesel's with the star pattern on the pistons is usually due to "custom" tuning - and anywhere from a little to a lot of timing added. Wouldn't be the first time I've heard Ford voiding a warranty due to custom tuning.
There's a few threads on here - and as well on Powerstroke.org that cover this more about the "star" pattern and what causes it.
But in all likely hood, you will not get this covered under warranty.
You're looking at either a new engine/heads or a rebuild.
that's why they're not even bothering to look at the bottom half of the engine - it's probably perfect.
It's the top half where all your problems are at.
The injector cleaner is not your cause...
Chances are - all the damage was done by your previous owner running some very hot tunes - and sorry to say, you're getting the bad results of that.
Those engines can be built to handle it - but sounds like someone didn't take the proper steps
Also - Which pistons were cracked - 7 and 8?
If so, also sounds like the tunes pushed a lot of fuel - causing the system to get stuck possibly in regeneration mode for the DPF - and when it does that, causes those to cylinders to generate a lot of heat to burn off the particulate caught in the DPF's.
And when that happens - it will melt stuff and crack pistons.
This was a known issue for the 6.4's and why people (aftermarket) came up with DPF delete kits.
There's a few threads on here - and as well on Powerstroke.org that cover this more about the "star" pattern and what causes it.
But in all likely hood, you will not get this covered under warranty.
You're looking at either a new engine/heads or a rebuild.
that's why they're not even bothering to look at the bottom half of the engine - it's probably perfect.
It's the top half where all your problems are at.
The injector cleaner is not your cause...
Chances are - all the damage was done by your previous owner running some very hot tunes - and sorry to say, you're getting the bad results of that.
Those engines can be built to handle it - but sounds like someone didn't take the proper steps
Also - Which pistons were cracked - 7 and 8?
If so, also sounds like the tunes pushed a lot of fuel - causing the system to get stuck possibly in regeneration mode for the DPF - and when it does that, causes those to cylinders to generate a lot of heat to burn off the particulate caught in the DPF's.
And when that happens - it will melt stuff and crack pistons.
This was a known issue for the 6.4's and why people (aftermarket) came up with DPF delete kits.
In all probability, this was all aftermarket tuning that caused this.
#5
06-12-2013, 12:38 PM
#6
06-12-2013, 01:13 PM
#7
06-12-2013, 04:42 PM
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#8
06-13-2013, 12:46 PM
Fleet Mechanic
As stated, im guessing the truck had a previous owner that had a high horsepower tune that permanently damaged the engine.
So many people thro these big tunes on, burn tires at every redlight & drive it like they stole it.
Then when it starts givin problems, they trade it in & the second or third owner gets the end result.
Most Performance tunes shorten the engines life IMHO
If Manufactures could have programming that makes more power, better mpg & the longevity was there,
Don't you think they would sell them this way & win ALL the bragging rights ??
So many people thro these big tunes on, burn tires at every redlight & drive it like they stole it.
Then when it starts givin problems, they trade it in & the second or third owner gets the end result.
Most Performance tunes shorten the engines life IMHO
If Manufactures could have programming that makes more power, better mpg & the longevity was there,
Don't you think they would sell them this way & win ALL the bragging rights ??
#9
06-13-2013, 03:07 PM
FTE Legend
Hence the need and want for aftermarket support.
Im a KTM guy as well, and I have a great example for you if yoru into the 950 ktm's. Think of the water pump, slave cylinder, and fuel pump upgrades.
#10
06-13-2013, 03:12 PM
Why would a vehicle manufacturer truly want to make an extremely reliable vehicle? I've talked to a few owners of various dealerships. Service now supports nearly the entire dealership. Educated consumers, social media and the Internet have brought car sales down to rock bottom prices. Allow room for aftermarket parts, void warranties and charge premium rates on service and repair. Just my $0.02.
#11
06-13-2013, 03:41 PM
#12
06-13-2013, 04:08 PM
Fleet Mechanic
Good points Guys 
I was an Assistant Svc Mngr at Ford Dealership for over 9yrs.
Service does carry the entire dealership.
The mentioned KTM bike mods are Fine Units, luckily all my Super Enduro OEM stock components are still working ok at 13k miles
Ok , back to the regular scheduled programming of the OP Bad Engine :
I was an Assistant Svc Mngr at Ford Dealership for over 9yrs.
Service does carry the entire dealership.
The mentioned KTM bike mods are Fine Units, luckily all my Super Enduro OEM stock components are still working ok at 13k miles
Ok
, back to the regular scheduled programming of the OP Bad Engine :
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