6.7L Powerstroke Turbo Failure Symptoms – How to Fix?

If you’re a 6.7L Powerstroke owner, then you know that your truck is packed with power.

But like any other machine, it’s not invincible.

A 6.7L Powerstroke turbo failure can be a costly repair, but it’s important to know the symptoms of a failing turbo so that you can take action before it’s too late.

In this blog post, we’ll outline some of the most common signs of a turbo failure on a 6.7L Powerstroke, and we’ll also provide some tips on how to fix it yourself.

So if you’re experiencing any of these symptoms, don’t panic – read this blog post and see how you can get your turbo up and running again!

Why Early 6.7 Powerstroke Turbos Fail?

The 6.7L Powerstroke Turbo is notorious for failing and unfortunately, there is no one definitive answer as to why this happens. But some of them might include:

• Weak ceramic ball bearings (2011–2014 models): These bearings often disintegrated under heavy load or high boost, especially in tuned trucks.
• Design flaws in the early Garrett GT32 SST turbo: The small single sequential setup struggled with heat and stress in demanding conditions.
• Factory defects and poor lubrication: Inadequate oil flow or impurities could quickly damage the turbo bearings.
• High exhaust temperatures: Excessive EGTs from towing or aggressive tuning accelerated bearing and shaft wear.
• Improper maintenance: Delayed oil changes or low-quality oil reduced turbo life.

Note: Ford resolved most of these issues with a redesigned turbo in 2014+ models, greatly improving reliability.

6.7L Powerstroke Turbo Failure Symptoms

Several telltale symptoms often appear when a turbocharger is failing.

Recognizing these early signs can help you pinpoint the problem before it leads to more serious engine damage.

1- Loud abnormal noise

One of the most common symptoms of a turbo failure is abnormal noise coming from the turbocharger itself.

If you hear any strange noises coming from under the hood, it’s worth investigating further because the loud noises can be a symptom of a faulty turbocharger.

2- Loss of power and poor acceleration

Other symptoms include a loss of power and poor acceleration.

6.7L Powerstroke is known for its speedy engine. However, if it fails your car may not accelerate as quickly or generate as much power as expected when you’re driving.

You could also experience sluggish response and a diminished overall power because of a bad turbocharger.

If you’re experiencing any of these issues, then it’s likely that your turbocharger is failing and needs to be replaced.

3- “Check Engine” light

Another symptom to watch out for is the “Check Engine” light – that is up on your dashboard.

This can be an indication that there is something wrong with the turbocharger or the engine itself.

Remember, the check engine light doesn’t specify which internal problem your vehicle is exactly facing, so it’s good to go to a mechanic to know why this is happening.

4- Excessive smoke from the exhaust

Excessive black smoke from the exhaust and an increase in engine temperature are other symptoms of a failing turbocharger.

If you notice this, it’s important to take action as soon as possible because it can be an indication that there is damage to the turbine or compressor blades.

5- The boost gauge

A boost gauge is a common feature on turbocharged vehicles, which displays the amount of boost being produced.

This is an excellent method to see how well your turbocharger is working.

A reduction in boost indicates that your turbocharger’s performance has been affected.

6- Leaking oil

Last but not least, one of the most common symptoms of a turbocharger failure is leaking oil.

If you see any oil leaks coming from under the hood, it’s likely that your turbocharger is the culprit.

Turbochargers rely on oil for lubrication and if there is a leak, it can cause increased oil consumption along with the turbo to overheat and fail.

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How to Fix and Prevent 6.7L Powerstroke Turbo Failure?

If you’re experiencing any of the symptoms listed above, here are a few things you can do…

1. Inspect for Leaks

If you notice any common turbo symptoms, start by checking the turbocharger for leaks. Even minor oil or boost leaks can cause performance problems and accelerate wear.

2. Clean the Turbocharger

If no leaks are found, clean the turbo. Use a can of compressed air to remove dust, debris, and carbon buildup from the turbo housing and blades. This simple step can improve efficiency and extend turbo life.

3. Check Oil Level and Quality

Inspect your engine oil. Low or dirty oil is a leading cause of turbo failure, as the turbo depends entirely on proper lubrication to withstand its extreme speeds and temperatures.

4. Seek Professional Help if Needed

If issues persist, consult a professional mechanic. They can diagnose internal problems like shaft play, bearing wear, or cracks and recommend the best solution before permanent damage occurs.

5. Consider a Turbo Upgrade (2011–2014 Models)

Owners of 2011–2014 6.7 Powerstroke engines with Garrett GT32 SST turbos should consider upgrading to the Garrett GT37.

This larger, more reliable turbo handles higher loads better. Retrofit kits are available, making installation easier.

6. Maintain Oil Quality (2015–2020 Models)

For 2015–2020 models, longevity comes down to high-quality full-synthetic engine oil and regular oil changes.

Turbos can reach temperatures up to 1000 °F, so proper oil prevents vaporization, deposits, and restricted flow that starve the turbo.

7. Why Full-Synthetic Oil Matters

Full-synthetic oil has fewer impurities, higher thermal stability, and better oxidation resistance.

Tests show it can perform up to 50% better than conventional oils under extreme conditions, keeping your turbo healthy and extending its lifespan.

Should You Replace 6.7l Powerstroke Turbo If There is a Failure?

Replacing a 6.7L Powerstroke turbocharger can be expensive and isn’t a simple DIY job. The cost can vary depending on the year and model of your truck.

On average, the turbocharger itself costs between $2,300 and $2,900, while labor charges typically range from $360 to $460. This makes proper diagnosis critical before deciding on a replacement.

Before committing to a full replacement, it’s best to take your truck to a qualified mechanic.

Experienced professionals can accurately assess the condition of your turbo, identify whether symptoms are due to minor issues like leaks or oil problems, and determine if a complete replacement is necessary.

A thorough inspection ensures you don’t spend thousands unnecessarily and helps you choose the best repair or upgrade option for your specific situation.

The Conclusion

If you’re experiencing any of the symptoms listed above, then it’s likely that your 6.7L Powerstroke turbocharger is failing and needs to be replaced.

While a 6.7L Powerstroke turbo failure can be a costly repair, it’s important to take action as soon as you notice any of the symptoms.

By doing so, you can avoid further damage and get your truck back on the road as soon as possible.