Table of Contents

The Short Version

  • 2011 to 2014 trucks use a Garrett turbocharger with two compressor wheels on one shaft. Rated output ended at 400 hp and 800 lb-ft after a Ford update.
  • 2015 and 2016 trucks use a larger Garrett turbocharger with a single compressor wheel. Rated output is 440 hp and 860 lb-ft.
  • Ford published a no-cost EGR cooler program (CSP 21M04) for certain 2011 to 2014 trucks. Ask a Ford dealer to check your VIN.
  • Ford changed the EGR cooler coolant source starting with 2015 engines.
  • Run the VIN at nhtsa.gov/recalls before you hand over money.

What Makes the 6.7L Different From Earlier Powerstrokes

The 6.7L engines in this range were built at Ford's Chihuahua, Mexico plant. Drivingline lists these firsts for a diesel pickup:

  • A compacted graphite iron (CGI) block
  • Reverse-flow cylinder heads, with intake on the outside and exhaust in the valley
  • An air-to-water intercooler fed by the engine's secondary cooling system
  • Bosch common-rail fuel system with a CP4.2 high-pressure pump and piezo injectors

It also uses EGR, a DOC, a DPF, and SCR with diesel exhaust fluid (DEF). Ford paired the 2011 truck with the 6R140 TorqShift six-speed automatic.

2011 to 2014 vs 2015 to 2016: The Differences That Matter

  2011 to 2014 2015 to 2016
Rated output 390 hp and 735 lb-ft at launch, then 400 hp and 800 lb-ft 440 hp and 860 lb-ft
Turbocharger Garrett variable geometry turbo, two compressor wheels on one shaft Garrett variable geometry turbo, single compressor wheel, larger than the one it replaced
High-pressure fuel pump CP4.2 Higher-volume CP4.2
EGR cooler coolant source Secondary cooling system High-temperature (primary) cooling system
Transmission 6R140 six-speed 6R140 six-speed

Sources for the table are listed at the end of this guide.

Power ratings by year

Ford launched the 2011 Super Duty at 390 hp and 735 lb-ft. Ford later raised the rating to 400 hp and 800 lb-ft, and it stayed there through 2014. For 2015, Ford announced 440 hp and 860 lb-ft for F-250 through F-450 models.

If a seller quotes a number that does not match the year of the truck, ask where it came from. A 2013 truck is a 400 hp and 800 lb-ft truck.

The turbocharger change

The 2011 to 2014 turbo has two compressor wheels on one shaft, a design Ford and Garrett marketed as "DualBoost". Drivingline describes it as restrictive and says over-speeding took many of them out of action over time. For 2015, Ford replaced it with a conventional single-compressor-wheel turbo with a larger turbine wheel and no wastegate. That change also removed the lower cast intake used on 2011 to 2014 engines. Both Drivingline and XDP describe a larger single-wheel turbo for 2015, and both say it can make up to 30 psi of boost in stock form.

When you inspect a 2011 to 2014 truck, ask whether the turbo has been replaced and by whom. When you inspect a 2015 or 2016 truck, you are looking at a different design.

The EGR cooler change

All 6.7L engines have two EGR coolers inside a shared housing. Drivingline and XDP both report that starting with 2015 model year engines, the EGR coolers are cooled by the primary (high-temperature) system only. On 2011 to 2014 engines, the first stage used the primary system and the second stage used the secondary system. The change reduced the heat load on the secondary system.

This matters when you see a coolant level problem. The truck has two cooling systems, each with its own reservoir. Find out which one is losing coolant before you decide what is wrong.

Ford Documents to Look Up by VIN

Ford has published official service documents that apply to specific builds. Ask a Ford dealer to look up your VIN, since status depends on build date, time, and mileage.

  • Customer Satisfaction Program 21M04 covers certain 2011 to 2014 Super Duty trucks with the 6.7L diesel, built from November 3, 2009 through March 14, 2014. Ford's stated reason is that the EGR cooler can become plugged with hydrocarbon or soot at high mileage. The program provided a no-cost cooler replacement when code P0401 and/or P2457 was stored, for 11 years or 120,000 miles from the vehicle's warranty start date, whichever came first.
  • Emissions Recall 21E01 covers certain 2013 to 2016 Super Duty trucks with the 6.7L diesel. Ford's dealer notice (filed with NHTSA) says the engine software contained an error that kept the check engine light from coming on when a certain front NOx sensor fault was present. The recall reprograms the PCM. Ford paired it with Customer Satisfaction Program 21N02, which extended front NOx sensor warranty coverage for P2201 faults found after the recall. That program expired December 31, 2024. After that, the sensor falls back to the original warranty terms. If you buy a truck in this range, ask whether 21E01 was completed. A truck that shows P2201 now is a repair you pay for.
  • Technical Service Bulletin 12-11-11 covers certain 2011 trucks built on or before March 29, 2011. Ford lists symptoms of an engine that runs rough or will not crank, with glow plug circuit codes P0671 through P0678. Ford later updated the bulletin as TSB 14-0127. A 2011 truck from early in the build run deserves a VIN check and a question to the seller about prior engine work.
  • Technical Service Bulletin 13-6-5 covers 2011 to 2012 trucks with a check engine light and P0401. Ford's procedure calls for a self-test, and the cooler core is replaced only when P2457 also appears.

P0401 alone does not prove the cooler is bad. If the seller says the EGR cooler "was done," ask for the repair order.

Also run the VIN at nhtsa.gov/recalls. NHTSA lists open and closed campaigns for each truck. Examples: Ford recalled certain 2011 F-series trucks built October 25 to November 20, 2010 for a body control module concern (NHTSA 11V128), and certain 2012 heavy-duty trucks built September 12 to 22, 2011 for a brake shift interlock switch (NHTSA 11V582). Whether either applies to a truck is a VIN question.

Pre-Purchase Inspection Checklist

You are buying a work truck with a lot of systems. Spend the money on a diesel shop inspection, and bring this list.

Paperwork

  • Service records, especially anything involving the EGR cooler, turbo, DPF, or DEF system
  • Repair orders for any coolant loss
  • Proof that Ford programs were handled, where they apply
  • A VIN recall and program lookup

Scan and test drive

  • Scan for stored and pending codes. Look for P0401 and P2457 (EGR), P2201 (front NOx sensor), P0671 through P0678 (glow plug circuits), and P2002, P2463, or P242F (DPF efficiency, soot accumulation, ash accumulation).
  • Watch for derate warnings and any message about DEF or exhaust fluid.
  • Check how the truck behaves when towing or under load, if the seller allows it.

Under the hood and underneath

  • Look at both coolant reservoirs. Note levels and signs of top-offs.
  • Look for coolant residue around the EGR coolers and the exhaust side of the engine.
  • Check the DEF tank, lines, and filler area for damage or crystallization.
  • Look at the exhaust system for signs of prior repairs or modifications.

Modifications

  • Ask directly whether the truck has been tuned or has any emissions hardware removed. If it has, ask who did the work and whether the original parts are still with the truck.
  • Check the truck's emissions label and ask the seller for details. Rules on modified emissions equipment differ by state and by vehicle weight, so confirm what applies where you register the truck.

If You Plan to Modify It Later

Many buyers in this model range plan upgrades after the purchase. Two things to keep in mind:

Fitment splits at 2015. EngineGo's EGR kits for this range are listed separately: one for 2011 to 2014, and one with a coolant bypass for 2015 to 2016. Buying the wrong one wastes time and money. Check your exact build before you order. The same logic applies to tuners, which are matched to model years.

Cab & Chassis trucks are a separate case. Check the product page for Cab & Chassis exclusions before you order. Important: Not compatible with Cab & Chassis trucks unless the product page says otherwise.

Compliance. Some emissions-related products are intended only for off-road, race, or non-public-road use where permitted. Check federal, state, and local laws before purchase and installation. Customers are responsible for confirming compliance. A "for off-road use" label does not change how a certified road vehicle is treated under federal law.

Tuning. Some emissions-related exhaust modifications may require tuning to address check-engine lights, diagnostic codes, or engine calibration. Plan the full setup before the first bolt comes off.

Installation. Use jack stands or a lift, let the exhaust cool, and wear protective gear. Professional installation is recommended where appropriate. Tuner returns can be more limited than other parts, so read the return terms before you order.

Frequently Asked Questions

Which 6.7L model years are covered by this guide?

2011 through 2016 F-250, F-350, and F-450 Super Duty trucks with the 6.7L diesel. Chassis cab trucks need a separate fitment check.

Is a 2015 or 2016 truck a different engine than a 2011 to 2014 truck?

Same displacement, same basic architecture, different turbocharger, higher power rating, and a different EGR cooler coolant source. Treat them as two groups when you shop for parts.

Does the 2011 to 2014 EGR cooler program still apply?

Ford's program had time and mileage limits that run from each truck's warranty start date. Ask a Ford dealer to look up your VIN.

What oil does my truck take?

Use the capacity and grade in your owner's manual for your exact year.

Can I check fitment before I order parts?

Yes. Send your year, engine, cab style, and current exhaust setup to EngineGo support and they can confirm fitment first.

Know What You Are Buying, Then Choose Parts That Match

A used 6.7L Powerstroke can be a good truck. The years that are right for your budget depend on what you check before you buy. Pull the VIN history, scan for codes, and find out which cooling system is losing coolant.

When you are ready to upgrade, shop the 2011 to 2019 6.7L Powerstroke collection, check your year, engine, cab, and bed against the Vehicle Fit Guide, and send your truck details if you are not sure. Most orders are processed the same or next business day, excluding Sundays, and most packages arrive within 3 to 5 business days after leaving the warehouse. Free shipping applies to orders shipped within the continental United States. Unused, uninstalled parts in original condition can be returned within 45 calendar days through the RMA process.