Here is my saga with my 2011 F-250 6.7 PSD:

I bought the truck used from a dealership that had reacquired it from the original owner due to a series of problems, most notably failures in the fuel injection system. Before reselling the truck to me, the dealership replaced three separate injectors before replacing the entire injection system (pump, injectors, lines, etc., except the fuel tank itself).

Fast forward to me owning it. After a month of it running completely fine with no noticeable issues, my check engine light comes on. Take the truck to a new dealership in my area, and the fuel injector for the #5 cylinder isn't working properly. Fuel injector replaced. Another week goes by with no issue and the light comes on again. This time it indicates poor cylinder contribution from the #5 cylinder. The head of the service department at the new dealer diagnoses low cylinder compression and says I need a new engine. Apparently, as I was told, this is because to diagnose the root cause of the problem (bad piston, cracked cylinder wall, etc.) they have to tear down the engine, and once they do that it is a matter of cost as to whether they rebuild it or just drop a new one in.

The truck ends up sitting at the dealer for two months as Ford corporate decides what to do, and in the mean time replaces all of the PCMs on the truck, along with more fuel injectors. Ford thinks they have solved the problem initially by doing so, but during a road test the truck stalls. I officially get a "new" engine, which I was lead to believe included everything except my original turbo, intakes, filters, and a couple of other things.

I have now had the truck for over a month with no issues. Put over 1000 miles on it in addition to the 300 the dealer did. Check engine light comes on today, get it checked out at AutoZone, and it comes back as poor contribution from the #1 cylinder.

I place the odds at this happening to two different engines in the same truck at "astronomical". I cannot think of what could be causing this, but I'm at the point where I'm even considering fuel tank delamination like in the 6.0 era. Any help would be so much appreciated, the truck is going back to service tomorrow.

 

I wish you luck, because you don't appear to have any. I don't mean that mean spirited at all either. I have not heard of any issues like this thus far. Hopefully Crystal can chime in and help you. Good luck!

 

Thanks man, I do appreciate it. I'm at such a loss at this point.

 

Truck or Chassis?

If Chassis then maybe a fuel tank issue as those are the only ones that I know of with steel tanks.

I am thinking fuel problems.

when you had the new motor did they put in new fuel filters?

 

Truck, crew cab with a short bed. And I believe they put in completely new filters with the new engine, and definitely when they replaced the injection system.

 

My concern is fuel quality here. Buy your fuel at the same location all the time? What about draining of the separator? How often?

 

Unfortunately I haven't really had the truck long enough to drain the separator regularly, but when I did have it I did it monthly. I always buy diesel from name-brand stores (usually Shell) and have all of my receipts. I have never gotten any water in fuel warnings nor was there any indication of that when the engineers did a tear down.

 

Here we go ... not another " in the dealer shop for 80 days " thread .... I'm getting sick now .

 

Two months is a long time. Now he gets to give it up again for a similar repair.
That truck is a disaster.

In addition to the current issue, I think they need to replace the entire fuel system.
If engine and fuel system don't fix it, I don't know what else is left...

 

Jeebus, these threads are starting to make me think of looking elsewhere other than the 6.7L if/when I need to move on from my 7.3L

 

Bought mine at the end of August. Granted not that long but not one visit back for anything. Sitting at about about 3400 miles.

 

Purchased April. 12K+ miles with 10K+ towing 17K fiver. No problems.

 

Bought mine in April '13. 3,900 miles and we haven't been back to the dealer yet. Towing 16k+ pound fiver and couldn't be happier.

 

Sorry I can't help at all.
Good luck and keep us posted.

What was the diagnosis for the new engine? Cracked valve?

 

Don't know yet, but I'm taking it in today and will update. Just so everyone knows, I've got 55,000 on it, but I think it was probably a lemon off the line unfortunately. I do really believe in these trucks, which is why I haven't given up yet. If it came down to it, I'd still get another one.