2009 F250 Super Duty with 6.4 Powerstroke diesel. Teardown, diagnosis, and rebuild. A lot of things can go wrong with a 6.4 Powerstroke. Let's see how many I can have in one engine! Music by Bensound.
Brother, I really admire your patience and perseverance with this complicated truck. Amazing that you've done all this work on your own, inside your private tent garage. You make it look so easy, but I know all painful countless hours are not seen through your videos. Thanks for putting out these 6.4 vids; it's rare to see such thorough repair on these!
@@blackericdenice agreed. It appears some 6.4 owners think they should be able to get 300k+ out of an engine while hot-rodding it on those hot tunes constantly. If you treat the most reputable engines, like the old 7.3 or 5.9 Cummins, bad and jacking them up outside their designs, they will leave you in the road.
ive got a 2008 DRW 6.4 with 155k on her. bought it used back in '20 with 118k at the time. so far she has been great, no issues at all other than cleaning the EBP sensor (knock on wood). im well aware these engines are not the most popular but at the end of the day, it can be your best friend or worst enemy based on how you treat them. now, im no where near inclined to advise on owning a diesel but believe it or not, there are quite a few 6.4s out there with tons of miles and zero to minimal issues. the common thread is strict maintenance but also never letting a drop of untreated diesel pass through. we all know ULSD causes issues and there are lots of places with "bad" fuel. i use "hot shot secret" but also add stanadyne lubricity formula so im double treating EVERY tank. is that overkill? maybe so, but a few more dollars per tank is well worth it to me. i had an oil sample sent off to blackstone labs and it came back exceptional so im not changing anything. would i buy another 6.4? eh, probably not but i have nothing bad to say about em. great video, much appreciated..
Thanks! I was just explaining to my 18 yo son a few days ago that maintenance is the key to a long lasting truck. Gotta change that oil! If something breaks, fix it quickly before it snowballs. I think most blown engines start with a small leak that someone ignores; it only takes a second to blow an engine with low oil or coolant. The second leading cause is aftermarket modifications. I am still undoing years of abuse and neglect from the previous owners of my truck.
After pulling the oil pan and seeing all that glitter I wouldn’t have even gone further into the engine I would’ve started looking for a replacement 😅 I applaud you and what a great learning video.
You would turn the key on 10 times not starting. You'll hear the lift pump putting fuel to the high pressure pump. You've done some amazing work that most of us with a 6.4 wouldn't dream of doing
Started watching your channel when considering purchasing a 6.4, I really admire your patience and overall demeaner. Especially keeping faith involved. I ended up getting a 6.7, and it has been well to me. I hope you ended up travelling a similar path. Love the content, keep up the good work.
Thanks for the content. You are an inspiration for me, it seems like im working on my truck every 6 months or so, sometimes gets very overwhelming, im greatful for the Internet and guys like you for posting content like this, helps us viewer's out tremendously. I own a 3rd gen 5.9 cummins that was abused and neglected, i know very little on the powerstroke and really dont care to, but this video helped me out a lot. God bless
My 6.4 does this from time to time I had to purge the air from the fuel lines like you did with the jerry can about 12 times, turning the key and letting it crank. After the twelve time started right up
As someone who has rebuilt a duramax, I feel your pain. I bought my truck with a melted piston because of a bad injector. From what I can tell, your crank journal must have plugged, but it's hard saying if the bearing caused the plug and the issue compounded. Hopefully it stays fixed for a while!God bless!
@BarnTech It was not what I expected. Our dorm had mold in the A/C system, so we are back home in Colorado doing online college. God's plan is different than mine. I pray regularly for him to slam the door on anything he doesn't want me to have, and thus far, he has done just that. That being said, he always opens another door. Online college will be about a quarter of the cost of in person, for the same degree. Plus, I am able to make and keep more money over the summer working on my projects than if I was in lynchburg VA. It was still sad to leave my new friends, but we have phones, so we still talk regularly. I guess life is like a project truck. You expect one issue, but you find several others that require a total rebuild! However, rebuilding can make it stronger and better than it ever was before. I finally got my transmission overheating issue on my Duramax fixed, so I continue mobile repair. I also have a 1993 ford f250 7.5l that I am rebuilding. God bless!
I just wished you had a 6V-53T or 6V-71T or maybe even a 318(8V-71T)and been done with it. Every bolt on it has been worn slick by your fingers. It makes me sick that you've had to wear it out so much but it's sure a labor of love and the Good Lord has sure been right there with you. Maybe some Delo 15/40 oil would help. bcbloc02, the machinist in Kentucky says that it and deere oil are the only ones still formulated for flat tappets. I run it in everything here but the car and saw it hold a 980G Cat loader together for 24K hours with only a valve cover gasket replaced. I ran the loader and it was still going when I left. All I CAN say is PRAISE GOD and drive that thing. I'm a diesel freak but not the new ones AT all. God Bless and Thanks for keeping this for a record!
@@barntech2291 Pal contractor down the loop ghot one in a ton dump. Sweet running at 1st but then the motor came unglued. I think it was tax time and he got another motor but not sure. I still like my Delo oil. God Bless Yall!
Holy cow you went in deep down a rabbit hole on that. I just inherited a 2010 6.4 from my step dad with 290k on the clock. Not sure about it’s history. I know it’s leaking oil like crazy and some coolant disappears. I have it at a shop right now and they said it has a lot of blow-by. They are getting ready to do a compression test. Wish I had your skills and knowledge. Feel like I’m going to need it.
@justinmanship5431 One of my earlier videos addresses 6.4 blowby. It’s probably the #8 piston. DPF regen causes piston #8 to crack. Knowing what I know now, I would pull the glow plug and stick a camera in there before I even did a compression test. Good luck!
@@barntech2291 Oh okay, I’ll definitely check that out. It’s been EGR and DPF deleted but I don’t know at what point in history that happened. I know my step dad bought it at 200k and on the way home it started acting up. The dealership took it to a diesel shop and they replaced the #8 rocker arm. My step dad says since then it’s leaked oil pretty badly. He was supposed to take it back to that mechanic but it was in Oklahoma and we live in Missouri, so he never did. He said the mechanic said he probably messed up the valve cover gasket. That’s pretty much all the history I have on it.
@@barntech2291 Heard back from the shop. They are seeing low compression on cylinder 2 and more than a 10% variance on another. Told me to just drive it until it dies. Once I get my shop built maybe I’ll go down the same rabbit hole you did.
“Drive it until it dies” doesn’t sound like good advice if you have bad blowby and two cylinders with low compression. Then again, if you are paying a shop to do the work it might cost more that the truck is worth to fix it. I would stick a Harbor Freight camera in the glow plug holes to see what’s going on.
Mine has 323K and no blow by, but was deleted early on in life. Keeping my fingers crossed and staying on top of filters and maintenance. I do have a Cummins here but love the power my tuned truck has. This has always been a highway truck towing so no short hop city life.
I just purchased a used 6.4 with about 230k on the truck, it’s was an old farm truck, I purchased it at an auction site unseen, it was involved in a front end accident not so bad, the radiator is gone, blew the power steering box out, and tweaked the front frame a little bit. I am having it sent out to a frame specialist to recenter everything and he is the best in my area, then I will send it out to a local diesel repair shop to have them look through it because yes I know the problems that a 6.4 can have. It looks like since this truck was a farm truck, it has been deleted and what I can tell tuned but not confirmed I just hope the truck will last for what I need it for 😅
Someone please watching this video sponcer this gentleman a 5.9 or 6.7 Cummins to put in this truck to make it reliable again!!, Man u are a patient man, there is no fxxking way i would have went through the trouble that u have and the time and waisted labor and it still be a 6.4 night mare sitting under there,
Good job.great video. Have to say I love your shop. Certainly works better than being out in the environment. This is my second time I have come across your channel. Looking forward to seeing more from you. My 08/6.4 is in the trany shop after only 130k miles 😢. She's been pulling a 30ft 5th wheel most of her life, or a work trailer. But only like less than 250k miles with great maintenance looks like $6k 😢
I appreciate the encouragement! I am amazed at how unreliable these trucks are. I have worked on a lot of stuff, but I have never seen something break in so many different ways. Great for CZcams content; terrible for daily driving!
I would change the oil filter at least 3 times rince the filter in diesel and check with a magnet if there is metal flakes each time you switch the filter.
I'm finishing up my rebuild at 365k after my oil cooler plugged up and a lifter ate itself away on my cam during a 2400 mi vacation. I bought a remanned short block and damaged a HP line while installing it back in the truck. Of course i found the leak 2 days after I finally got it back on the road. Anyway, I feel your pain....my only question is: If you chose to buy a new crank. after metal contamination, why "check" the lifters, oil cooler, turbo lines, etc? I would think you'd want all of that replaced without question. I re-machined the heads, lapped valves, seals, BUT new: oil cooler & pump, rockers. bridges, pushrods, lifters, turbo innards, and a new fuel pump (just because of the mileage). Flushing the cooler? why bother when they're so cheap. oil flow is from the cooler to the filter and then simultaneously to the turbos and lower block sooo. Hell of a video! Great job!
Flushing the oil cooler was a waste of time. I tried, but I could not remove all the debris. I ended up replacing the cooler and flushing everything else (turbo rebuild, etc). It takes more time to do it this way but it my philosophy is “It only needs what it needs.”
Dude your a 100% American bad ass so cool that you did all that work all by your self in your garage is just insane did u go to a diesel tech school or just learned over the years ?
Wow. Major props to you sir. You did a full blown engine over haul on a 6.4 - at your house! Also, can you show more details on how you lift up the cab? Thanks.
Yep! The injector lines also leak if you don’t follow the directions. The part about snug down the injectors and then loosen them before torquing the lines is especially important.
When the boost boot blew off on my dad's 6.0, weighin in at over 8,000 lbs with 3.73 gearin & 32.7 inches tires, floored it had worse acceleration than my na 7.3 idi with 4.10s & 31.7 inch tires weighin over 6,000lbs does. Limped it over a mile home put the boost boot back on & the power came back
Ya. I have read that those fuel lines are a must to replace if you crack them loose you have to replace them no getting around them. To bad they don"t come come with a flange and a crush washer system or something. Anyway thanks Ford. But I guess thats after going through the HP pump so that I guess is understandable. Well you got some patients going on there bro.
Yeah I’m not sure a crush washer could handle 24k psi. It would be nice if you could repair a leak without lifting the cab or pulling the turbo though.
I’ve seen Cummins and duramax’s do the same exact thing. Clean the block and throw a new crank/rods in it. If you’re worried about the bore then sleeve it. Take your time and don’t rush. Don’t let people talk you into Cummins swapping because pretty soon all those guys will have to swap back or get rid of their trucks once the epa has their way.
@@barntech2291 they’re definitely the “Karen” of the powerstrokes but they’re capable of making the most power out of all of them. Mine let me down last Sunday (water pump) and I had to drive a 6.0 instead with a hot tow tune. Needless to say I’m ready to get my 6.4 back because 6.0’s are lazy compared to the 6.4🤷🏻♂️
To each his own I like mine nothing in the diesel lineup sounds as good to me now in factory form it will have some problems once you address the egr put some studs in it they are actually pretty good I know it gets hate but some of the bad rap they get is the owners neglecting them
Sorry for the sarcasm. There is a lot you can do to make the 6.0 and 6.4 engines more reliable. There is also a TON of power from them. Whenever I fix mine it seems to break somewhere else, though.
I had to rebuild my 6.4 after it blew a head gasket and had a frozen roller on one on the lifters. It also trashed the cam. With all the debris in the engine, it would have been a good idea to remove the oil pump and flush the oil passages in the block before assembly.
That thought crossed my mind multiple times! I have owned three Dodge Rams, and the only problem I ever had was my fault (burned out transmission by over loading).
I ended up replacing the lift pump after publishing this video. Cleaning the valve helped, but it still sounded funny so I replaced it. Truck is running great now! Looking for a new home :-)
6.4s are interesting, it seems like there’s duds that’s no matter how much you put into them they won’t ever work right. And there’s others that are dead reliable and run forever even if you beat on them
I really admire your approach or concept with this difficult project. I know how you must have felt after it finally started🙂. Even without a shop lift, you are still able to lift cab! Please how and where did you attach the ropes to the cab to lift it?
I put the front straps by the front body mounts and the rear straps on the rear running board mounts. It puts a little pressure on the back doors but they bounce back.
@@barntech2291 Thank you for the explanation! I saw the video you tried to explain it a little bit, but I could not see how you did it. Please can you make a special video about this clearly showing how you attached those straps to the cab body? This will greatly help me with my cab removal using a gantry crane!
How could you keep from taking a sledge to that truck? I have a 6.4 and I can’t get myself to take the time (and money) to fix it once. After watching you work on this truck I think I’ll be getting rid of mine. Thanks for posting your work, I was beginning to think you quit yt but I now understand . Btw what truck did you buy?
Haha! The sledge would affect resale value too much. I made up my mind to buy a new truck before this one even made it home on the wrecker. I think it should be dependable now that I have fixed it, but I also thought that the last two times I rebuilt it. I guess that’s for the next owner to find out :-) As for the new truck, I went back to Dodge. They never did me wrong and you can’t beat the value.
Curious how many miles on this. Did it have the emission system still on it? I have been very lucky with my 2008 6.4 that was deleted since nearly new. 323,000 miles with just a starter and batteries. Auto trans replaced at 278,000.
I bought it with a cracked piston at 159k. It was already deleted, so I’m not sure that helps. I don’t know why some get lucky with the 6.4 and others don’t.
@@barntech2291Yeap! Believe or not some of us are still wating on the vid bud. Be really helpful to see how u got that cab up. Great great work uve done sir! Inspirational.
Lots of people asking for this. My next video will include a little about my homemade lift. I am waiting for parts to finish that video. Yes, the cab is off again!
I suspect the cracked crankshaft started it all. Something I missed in the previous rebuild. That led to the rod bearing, which plugged the oil filter. Once the oil filter split that took out the turbos and other bearings.
There's no reliable diesel truck known, 7.3 and 5.9 wouldn't break because they were so underpowered. 6.4 Had the potential to tune and get alot of power out of it deleted. The new ones are worse nothing but issues with emissions and clogging exhaust filters.
bought one last yr with 175k, after hearing all this , i am sick over the 6.4. havent used it much. would u recommend getting rid of it or ??? it runs good with new injectors and new steering parts. i would have to hire anything major done.
You can’t beat the power! Most people have better luck than me. I think mine was abused and neglected by previous owners. I have fixed most of that now. Unfortunately, I had to buy a new truck because I could not wait for this one to get back on the road. Best advice is to keep up with maintenance so it doesn’t get like mine.
@BarnTech Purchased a non running 08 for my son and I'm curious if you could shed some light on your lifting system for the cab. Any bits of wisdom / advice would be appreciated.
Haha! I don’t think what I did was exactly wise. It got the job done and nobody got hurt though. I used two 2x10 with 2x6 screwed on top and bottom like an I-beam. I bought lift straps, chains, and comealongs from Harbor Freight.
@@barntech2291 czcams.com/video/trY3FhkX_8A/video.htmlsi=L1nfFIYkpZryWvNc this was a really informative talk on the 6.4L. Apparently fuel leaking into the oil is common and causes main journal destruction.
My best guess is I had a bad injector that caused excessive wear on rod #2. I have pulled the injectors to check them out. Will update the comments if I find anything.
@@barntech2291 me thinks that on these diesel's, every fuel system component should be replaced when the miles have added up. I did mine at 197,000, now the hpfp was going bad but only that one item. If we replace that fuel pump only we'd be crazy without doing the whole thing. You sir can save a huge dime doing it yourself. Thanks for posting. I re used the fuel rails and cooler, those are still good.
If you have any issues the fuel cooler will need replaced. My cooler had a bunch of glitter from the HPFP. I flushed for a long time and it kept coming.
Bullet proofing kills these. I have rebuilt tuned 6.4s many times. Never have had to rebuild any stock ones. Tuning takes out bearings and the cam. If you don't get all new parts you will be plagued forever. Don't be cheap with a 6.4. They bite.
@@barntech2291 Yes, you trade being on the side of the road for a sensor for being on the side of the road for a crankshaft or cam. Was your cam good? I have changed many in 6.4s because they wear through the case hardening. They wear and then start wearing the lifter roller into an egg shape. Then you get an intermittant miss.
Cam was good. Issue seems due to spun rod bearing. I have no idea how tuning could cause this, unless it raises the rev limit. I don’t think my engine ever went much above 3k rpm though. Is that what you think happened?
@@barntech2291 They advance the injection timing with the tunes. The increased pressure from the advanced timing hits hard on the top of the piston, if it doesn't crack the piston cup ( that's why you decup the pistons for high performance ) the shock force is transfered to the bearings. It will keep smashing the bearing. I see it with the center main bearing most of all. you will see a copper spot on the lower bearing from it getting pounded. The 6.4 runs perfect untill it's blown up. The 6.4 despite that is my favorite powerstroke to make power with. They just don't make it very long. This is what I see and I'm sure there are plenty of people that will dissagree
I did a lot of cleaning off camera. I show just enough to get the gist of what I am doing. I hope anyone who goes this deep in their engine knows how to read between the lines. For everyone else it’s entertainment.
I enjoy working on engines. I do not enjoy working on my daily driver. I am working on one last video of this truck and I will move on to other projects.
I wish it was that easy! The noise was turbos but the damage was much more extensive. It turns out my fuel issues are not over either. Keep an eye out for the next (and hopefully final) video.
Shame on ford for putting this engine on the road. Many people have spent good money for a diesel in faith they bought a reliable HD vehicle. So sad and again shame on ford.
It’s hard to defend Ford, because this is the most unreliable engine I have ever heard of; it breaks in more ways than I can imagine. However, please consider two facts: 1) The US EPA did not allow Ford to continue making the 7.3, and 2) No other light duty truck can match the torque of a 6.4 in its stock configuration. I love my new Dodge, but I miss the power of my old 6.4.
@@barntech2291 Blame the EPA for changing regulations so quickly during this period that Manufacturers could not design and fully test those 'air purifiers' before releasing them. These motors in Internationals larger trucks did not have all that crap and never had issues.
I did a lot of cleaning measuring and torquing off camera. I show just enough to get the gist of what I am doing. I hope anyone who goes this deep in their engine knows how to read between the lines. For everyone else it’s entertainment.
I find it hard to believe, but I had two problems that day. What stopped me in my tracks was the HPFP (new video coming soon), but when I coasted to the side of the road my main bearings were seized. The fuel system and oil system in this engine are completely separate. What are the odds that both would catastrophically fail at the exact same time?
I can tell you exactly what that is.... It's a spun rod bearing, I admire your patience and video's but a 6.4 power joke is the biggest POS engine ever produced, just a fact, if you want to keep the truck do a Cummins swap and be done with it, 6.4 is nothing but a hole to throw money in.
I talk about it a little in my latest video. I used 2x10’s with 2x6’s screwed on top and bottom like an I-beam. The 2x10 in the rear of the cab cracked. I probably should have screwed two of them together with the 2x6’s on top and bottom.
6.4 are as bad as a 6.blow....my 2001 7.tree f2shity has 980 thousand miles all original Michigan truck works construction and plowed every winter of its life...still stroking and purrs like a kitten 😸... 13 letter shitspreader INTERNATIONAL best diesel ever made. I've been driving it for 23 years now....try that dodge Chevy or Toyota....
No it doesn't.. international doesn't even claim engine life past 250-300 before a rebuild. And Toyota and Cummins both product million miles engines often.
@@barntech2291 yeah that definitely plays a factor. I bet where I’m at that’ll be around 6 to 10k. I just built a little walk out porch with a ramp for my moms camper and that costed around 1k
Brother, I really admire your patience and perseverance with this complicated truck. Amazing that you've done all this work on your own, inside your private tent garage. You make it look so easy, but I know all painful countless hours are not seen through your videos. Thanks for putting out these 6.4 vids; it's rare to see such thorough repair on these!
Rare to get anybody to even admit to having one!
@@lewiemcneely9143 My neighbor has one and it run fine. Maybe if people stop trying to make them fly or run on addictive.
@@blackericdenice agreed. It appears some 6.4 owners think they should be able to get 300k+ out of an engine while hot-rodding it on those hot tunes constantly. If you treat the most reputable engines, like the old 7.3 or 5.9 Cummins, bad and jacking them up outside their designs, they will leave you in the road.
"the Lord gives and takes away" loved that part.
recently purchased a 6.4 that has treated me well aside from needing normal maintenance. Thank you for the high quality content!
ive got a 2008 DRW 6.4 with 155k on her. bought it used back in '20 with 118k at the time. so far she has been great, no issues at all other than cleaning the EBP sensor (knock on wood). im well aware these engines are not the most popular but at the end of the day, it can be your best friend or worst enemy based on how you treat them. now, im no where near inclined to advise on owning a diesel but believe it or not, there are quite a few 6.4s out there with tons of miles and zero to minimal issues. the common thread is strict maintenance but also never letting a drop of untreated diesel pass through. we all know ULSD causes issues and there are lots of places with "bad" fuel. i use "hot shot secret" but also add stanadyne lubricity formula so im double treating EVERY tank. is that overkill? maybe so, but a few more dollars per tank is well worth it to me. i had an oil sample sent off to blackstone labs and it came back exceptional so im not changing anything. would i buy another 6.4? eh, probably not but i have nothing bad to say about em.
great video, much appreciated..
Thanks! I was just explaining to my 18 yo son a few days ago that maintenance is the key to a long lasting truck. Gotta change that oil! If something breaks, fix it quickly before it snowballs. I think most blown engines start with a small leak that someone ignores; it only takes a second to blow an engine with low oil or coolant. The second leading cause is aftermarket modifications. I am still undoing years of abuse and neglect from the previous owners of my truck.
Mines been great, but turbos went out and I’m Ganna do the oil cooler while I’m there
After pulling the oil pan and seeing all that glitter I wouldn’t have even gone further into the engine I would’ve started looking for a replacement 😅 I applaud you and what a great learning video.
Trying to keep cost down. Salvage engines for these trucks are crazy expensive!
Your patience and perseverance are second to none! Well done !
You would turn the key on 10 times not starting. You'll hear the lift pump putting fuel to the high pressure pump. You've done some amazing work that most of us with a 6.4 wouldn't dream of doing
Yeah, I wish it was that easy. Turns out I had more serious fuel issues. New videos on the way!
Started watching your channel when considering purchasing a 6.4, I really admire your patience and overall demeaner. Especially keeping faith involved. I ended up getting a 6.7, and it has been well to me. I hope you ended up travelling a similar path. Love the content, keep up the good work.
Thanks for the content.
You are an inspiration for me, it seems like im working on my truck every 6 months or so, sometimes gets very overwhelming, im greatful for the Internet and guys like you for posting content like this, helps us viewer's out tremendously.
I own a 3rd gen 5.9 cummins that was abused and neglected, i know very little on the powerstroke and really dont care to, but this video helped me out a lot. God bless
Glad my video blessed you :-)
Unbelievable SHOP for the
6.4 .. hello , I have a 6.4 ,
don't anticipate a bearing
disintegration .. NICE VIDEO 👍
Yeah, I didn’t see that coming
My 6.4 does this from time to time I had to purge the air from the fuel lines like you did with the jerry can about 12 times, turning the key and letting it crank. After the twelve time started right up
Not long after this video I replaced the lift pump. The old one still worked but it was noisy and seemed to struggle a little. Primes up better now.
As someone who has rebuilt a duramax, I feel your pain. I bought my truck with a melted piston because of a bad injector. From what I can tell, your crank journal must have plugged, but it's hard saying if the bearing caused the plug and the issue compounded. Hopefully it stays fixed for a while!God bless!
Glad to hear from you Greenhill! How was your first year of college? Stacked up a bunch of projects for the summer?
@BarnTech It was not what I expected. Our dorm had mold in the A/C system, so we are back home in Colorado doing online college. God's plan is different than mine. I pray regularly for him to slam the door on anything he doesn't want me to have, and thus far, he has done just that. That being said, he always opens another door. Online college will be about a quarter of the cost of in person, for the same degree. Plus, I am able to make and keep more money over the summer working on my projects than if I was in lynchburg VA. It was still sad to leave my new friends, but we have phones, so we still talk regularly. I guess life is like a project truck. You expect one issue, but you find several others that require a total rebuild! However, rebuilding can make it stronger and better than it ever was before.
I finally got my transmission overheating issue on my Duramax fixed, so I continue mobile repair. I also have a 1993 ford f250 7.5l that I am rebuilding.
God bless!
I just wished you had a 6V-53T or 6V-71T or maybe even a 318(8V-71T)and been done with it. Every bolt on it has been worn slick by your fingers. It makes me sick that you've had to wear it out so much but it's sure a labor of love and the Good Lord has sure been right there with you. Maybe some Delo 15/40 oil would help. bcbloc02, the machinist in Kentucky says that it and deere oil are the only ones still formulated for flat tappets. I run it in everything here but the car and saw it hold a 980G Cat loader together for 24K hours with only a valve cover gasket replaced. I ran the loader and it was still going when I left. All I CAN say is PRAISE GOD and drive that thing. I'm a diesel freak but not the new ones AT all. God Bless and Thanks for keeping this for a record!
Thanks Lewie! In retrospect, I wish I had swapped in a 7.3 at the beginning. I would probably still be daily driving it. Praise God it is running now!
@@barntech2291 Pal contractor down the loop ghot one in a ton dump. Sweet running at 1st but then the motor came unglued. I think it was tax time and he got another motor but not sure. I still like my Delo oil. God Bless Yall!
Holy cow you went in deep down a rabbit hole on that. I just inherited a 2010 6.4 from my step dad with 290k on the clock. Not sure about it’s history. I know it’s leaking oil like crazy and some coolant disappears. I have it at a shop right now and they said it has a lot of blow-by. They are getting ready to do a compression test. Wish I had your skills and knowledge. Feel like I’m going to need it.
@justinmanship5431 One of my earlier videos addresses 6.4 blowby. It’s probably the #8 piston. DPF regen causes piston #8 to crack. Knowing what I know now, I would pull the glow plug and stick a camera in there before I even did a compression test. Good luck!
@@barntech2291 Oh okay, I’ll definitely check that out. It’s been EGR and DPF deleted but I don’t know at what point in history that happened. I know my step dad bought it at 200k and on the way home it started acting up. The dealership took it to a diesel shop and they replaced the #8 rocker arm. My step dad says since then it’s leaked oil pretty badly. He was supposed to take it back to that mechanic but it was in Oklahoma and we live in Missouri, so he never did. He said the mechanic said he probably messed up the valve cover gasket. That’s pretty much all the history I have on it.
@@barntech2291 Heard back from the shop. They are seeing low compression on cylinder 2 and more than a 10% variance on another. Told me to just drive it until it dies. Once I get my shop built maybe I’ll go down the same rabbit hole you did.
“Drive it until it dies” doesn’t sound like good advice if you have bad blowby and two cylinders with low compression. Then again, if you are paying a shop to do the work it might cost more that the truck is worth to fix it. I would stick a Harbor Freight camera in the glow plug holes to see what’s going on.
Mine has 323K and no blow by, but was deleted early on in life. Keeping my fingers crossed and staying on top of filters and maintenance. I do have a Cummins here but love the power my tuned truck has. This has always been a highway truck towing so no short hop city life.
I just purchased a used 6.4 with about 230k on the truck, it’s was an old farm truck, I purchased it at an auction site unseen, it was involved in a front end accident not so bad, the radiator is gone, blew the power steering box out, and tweaked the front frame a little bit. I am having it sent out to a frame specialist to recenter everything and he is the best in my area, then I will send it out to a local diesel repair shop to have them look through it because yes I know the problems that a 6.4 can have. It looks like since this truck was a farm truck, it has been deleted and what I can tell tuned but not confirmed I just hope the truck will last for what I need it for 😅
Good luck!
Someone please watching this video sponcer this gentleman a 5.9 or 6.7 Cummins to put in this truck to make it reliable again!!, Man u are a patient man, there is no fxxking way i would have went through the trouble that u have and the time and waisted labor and it still be a 6.4 night mare sitting under there,
If a generous subscriber gives me a Cummins I will gladly video the install. You gotta act fast before I sell the truck though :-)
Good job.great video. Have to say I love your shop. Certainly works better than being out in the environment. This is my second time I have come across your channel. Looking forward to seeing more from you. My 08/6.4 is in the trany shop after only 130k miles 😢. She's been pulling a 30ft 5th wheel most of her life, or a work trailer. But only like less than 250k miles with great maintenance looks like $6k 😢
I appreciate the encouragement! I am amazed at how unreliable these trucks are. I have worked on a lot of stuff, but I have never seen something break in so many different ways. Great for CZcams content; terrible for daily driving!
That's 250kms so like 140K miles and rebuild on the transmission
I would change the oil filter at least 3 times rince the filter in diesel and check with a magnet if there is metal flakes each time you switch the filter.
I am definitely going to keep a close eye on the oil if I keep the truck around. Since it was down so long I bought another truck though.
I'm finishing up my rebuild at 365k after my oil cooler plugged up and a lifter ate itself away on my cam during a 2400 mi vacation. I bought a remanned short block and damaged a HP line while installing it back in the truck. Of course i found the leak 2 days after I finally got it back on the road. Anyway, I feel your pain....my only question is: If you chose to buy a new crank. after metal contamination, why "check" the lifters, oil cooler, turbo lines, etc? I would think you'd want all of that replaced without question. I re-machined the heads, lapped valves, seals, BUT new: oil cooler & pump, rockers. bridges, pushrods, lifters, turbo innards, and a new fuel pump (just because of the mileage). Flushing the cooler? why bother when they're so cheap. oil flow is from the cooler to the filter and then simultaneously to the turbos and lower block sooo. Hell of a video! Great job!
Flushing the oil cooler was a waste of time. I tried, but I could not remove all the debris. I ended up replacing the cooler and flushing everything else (turbo rebuild, etc). It takes more time to do it this way but it my philosophy is “It only needs what it needs.”
Dude your a 100% American bad ass so cool that you did all that work all by your self in your garage is just insane did u go to a diesel tech school or just learned over the years ?
Thanks! I have rebuilt a gagillion gasoline engines but I am still learning diesel. I picked a humdinger with this one!
awesome to see it all fixed
For the moment…editing a new video as we speak…
the reason there was no bearing left on the rod side is because all the load os on the rod not the cap.
Good theory, but why was this bearing so much worse than the other seven?
Wow. Major props to you sir. You did a full blown engine over haul on a 6.4 - at your house! Also, can you show more details on how you lift up the cab? Thanks.
I show a little more detail on the HPFP and injector videos. I need to caution you though. What I did isn’t exactly safe.
youre one hell of a mechanic
Thanks. I believe God has given each of us gifts and abilities. It’s our job to figure out what they are and use them to glorify Him!
The fuel lines to the injectors and fuel rail are a one time use. They tend to leak if you reuse them
Yep! The injector lines also leak if you don’t follow the directions. The part about snug down the injectors and then loosen them before torquing the lines is especially important.
When the boost boot blew off on my dad's 6.0, weighin in at over 8,000 lbs with 3.73 gearin & 32.7 inches tires, floored it had worse acceleration than my na 7.3 idi with 4.10s & 31.7 inch tires weighin over 6,000lbs does. Limped it over a mile home put the boost boot back on & the power came back
As they say, there is no replacement for displacement.
Good job man!
Thanks!
Great video man.
Ya. I have read that those fuel lines are a must to replace if you crack them loose you have to replace them no getting around them. To bad they don"t come come with a flange and a crush washer system or something. Anyway thanks Ford. But I guess thats after going through the HP pump so that I guess is understandable. Well you got some patients going on there bro.
Yeah I’m not sure a crush washer could handle 24k psi. It would be nice if you could repair a leak without lifting the cab or pulling the turbo though.
I’ve seen Cummins and duramax’s do the same exact thing. Clean the block and throw a new crank/rods in it. If you’re worried about the bore then sleeve it. Take your time and don’t rush. Don’t let people talk you into Cummins swapping because pretty soon all those guys will have to swap back or get rid of their trucks once the epa has their way.
I considered lots of options but the quickest and easiest was to keep it stock. I am amazed at how fragile the 6.4 is though!
@@barntech2291 they’re definitely the “Karen” of the powerstrokes but they’re capable of making the most power out of all of them. Mine let me down last Sunday (water pump) and I had to drive a 6.0 instead with a hot tow tune. Needless to say I’m ready to get my 6.4 back because 6.0’s are lazy compared to the 6.4🤷🏻♂️
Yeah it makes a ton of power and it is fun to drive, but fixing it is like squeezing a balloon…it just pops out somewhere else.
An upgraded 6.0 would slide right in 😊
So I should replace the least reliable engine ever with the second least reliable engine ever?
To each his own I like mine nothing in the diesel lineup sounds as good to me now in factory form it will have some problems once you address the egr put some studs in it they are actually pretty good I know it gets hate but some of the bad rap they get is the owners neglecting them
Sorry for the sarcasm. There is a lot you can do to make the 6.0 and 6.4 engines more reliable. There is also a TON of power from them. Whenever I fix mine it seems to break somewhere else, though.
I had to rebuild my 6.4 after it blew a head gasket and had a frozen roller on one on the lifters. It also trashed the cam. With all the debris in the engine, it would have been a good idea to remove the oil pump and flush the oil passages in the block before assembly.
Hopefully your filter did its job. Mine did not
@@barntech2291 It did, but I ended up pulling the engine a rebuilt it anyway.
Time for a cummins swap
That thought crossed my mind multiple times! I have owned three Dodge Rams, and the only problem I ever had was my fault (burned out transmission by over loading).
Cummins i see every week.......dpf kilo diesel
s&s diesel in indiana has really good high pressure fuel pumps
I ended up replacing the lift pump after publishing this video. Cleaning the valve helped, but it still sounded funny so I replaced it. Truck is running great now! Looking for a new home :-)
6.4s are interesting, it seems like there’s duds that’s no matter how much you put into them they won’t ever work right. And there’s others that are dead reliable and run forever even if you beat on them
I have never seen anything break in so many ways. I hope I fixed them all :-)
I really admire your approach or concept with this difficult project. I know how you must have felt after it finally started🙂. Even without a shop lift, you are still able to lift cab! Please how and where did you attach the ropes to the cab to lift it?
I put the front straps by the front body mounts and the rear straps on the rear running board mounts. It puts a little pressure on the back doors but they bounce back.
@@barntech2291 Thank you for the explanation! I saw the video you tried to explain it a little bit, but I could not see how you did it. Please can you make a special video about this clearly showing how you attached those straps to the cab body? This will greatly help me with my cab removal using a gantry crane!
How could you keep from taking a sledge to that truck? I have a 6.4 and I can’t get myself to take the time (and money) to fix it once. After watching you work on this truck I think I’ll be getting rid of mine. Thanks for posting your work, I was beginning to think you quit yt but I now understand . Btw what truck did you buy?
Haha! The sledge would affect resale value too much. I made up my mind to buy a new truck before this one even made it home on the wrecker. I think it should be dependable now that I have fixed it, but I also thought that the last two times I rebuilt it. I guess that’s for the next owner to find out :-)
As for the new truck, I went back to Dodge. They never did me wrong and you can’t beat the value.
I assume thats a lifter eating the camshaft but ill find out by watching the video
If only it was that easy!
What a awesome effort....congratulations mate amazing work.....
Thanks!
Curious how many miles on this. Did it have the emission system still on it? I have been very lucky with my 2008 6.4 that was deleted since nearly new. 323,000 miles with just a starter and batteries. Auto trans replaced at 278,000.
I bought it with a cracked piston at 159k. It was already deleted, so I’m not sure that helps. I don’t know why some get lucky with the 6.4 and others don’t.
You may have mentioned in the video and i just missed it but how many miles you got on it?
Only 170k!
Good video's im interested in your homemade cab lift can you show a video on how you got that setup
I have gotten this question a few times now so I might make a short video
Thanks
@@barntech2291Yeap! Believe or not some of us are still wating on the vid bud. Be really helpful to see how u got that cab up. Great great work uve done sir! Inspirational.
"Just needs a turbo rebuild and a oil filter" (Better take the whole truck apart just to make sure.)
The saga isn’t over yet! Waiting on parts for my next video. You won’t want to miss this one!
I wish everybody would admit when they don’t know what they’re lookin at
The best way to learn something new is to try something you have never done before :-)
If you don't mind would you show your setup on how you feeling your cab.
Lots of people asking for this. My next video will include a little about my homemade lift. I am waiting for parts to finish that video. Yes, the cab is off again!
What ended up being the root cause of the failure?
I suspect the cracked crankshaft started it all. Something I missed in the previous rebuild. That led to the rod bearing, which plugged the oil filter. Once the oil filter split that took out the turbos and other bearings.
There's no reliable diesel truck known, 7.3 and 5.9 wouldn't break because they were so underpowered. 6.4 Had the potential to tune and get alot of power out of it deleted. The new ones are worse nothing but issues with emissions and clogging exhaust filters.
Complicated = unreliable. I have worked on a lot of engines, but I have never seen one this complicated (or unreliable).
What is the Odometer
Just 160k
Would a 5.9L cummins swap be a terrible idea?
I have seen several guys do that. If I buy another old Ford I will probably swap in a 6.7 Powerstroke though.
bought one last yr with 175k, after hearing all this , i am sick over the 6.4. havent used it much. would u recommend getting rid of it or ??? it runs good with new injectors and new steering parts. i would have to hire anything major done.
You can’t beat the power! Most people have better luck than me. I think mine was abused and neglected by previous owners. I have fixed most of that now. Unfortunately, I had to buy a new truck because I could not wait for this one to get back on the road. Best advice is to keep up with maintenance so it doesn’t get like mine.
Your oil filter cap looks a whole lot larger than OEM. I’d replace that before it kills your motor again.
Do you mean mine is taller? I think it looks like most of the other ones I see on Google (minus the billet ones and a few shorties).
Wix filters are taller and come with the cap that matches. Keep the short one for a Motorcraft.replacement.
@BarnTech
Purchased a non running 08 for my son and I'm curious if you could shed some light on your lifting system for the cab. Any bits of wisdom / advice would be appreciated.
Haha! I don’t think what I did was exactly wise. It got the job done and nobody got hurt though. I used two 2x10 with 2x6 screwed on top and bottom like an I-beam. I bought lift straps, chains, and comealongs from Harbor Freight.
It put more sideways pressure than I expected. If it hadn’t hit the barn rafter it probably would have crashed down
excuse me sir how many miles does this truck have? is it 2009 ford f250 6.4 turbo diesel?
Around 170k
Could this be caused by having it bored out and causing excessive stress on the journal bearings?
I have bored a bunch of engines and it never caused anything like this. It had to be lack of oil.
@@barntech2291 czcams.com/video/trY3FhkX_8A/video.htmlsi=L1nfFIYkpZryWvNc this was a really informative talk on the 6.4L. Apparently fuel leaking into the oil is common and causes main journal destruction.
No
I thought it was funny at the end of the video you were wearing a hat that said, LP while you were disassembling the Lift Pump 😅
Haha that hat is from a soccer team I used to coach. I need to make some Barntech hats :-)
I found out the hard way ofter I use some of the Market parts this is gonna happen
It was a Motorcraft filter and Mahle bearings! I’m not 100% sure which went first but glad I caught it before it threw the rod.
Oh the fate of the 6.4 😬 sorry brother!
Yep! It’s the gift that keeps giving.
don't worry I have the same problem with a 08 same it's your
I got mine running great but I already bought another truck. Hopefully it runs great for the next guy!
I got mine running great but I already bought another truck. Hopefully it runs great for the next guy!
Would you mind showing how you took the cab off in your shop?
Sure, I can put a little about my homemade lift in my next video.
🙏🏿✌🏿
Thanks!
Motor is shot ive heard that noise hundreds of times its a rod bearing gone
Yep! That wasn’t all though :-(
You are Job Jr.
I sure felt like it!
They all break down
Yep, some more than others though
That’s strange that’s not a common 6.4 issue that’s a strange failure
My best guess is I had a bad injector that caused excessive wear on rod #2. I have pulled the injectors to check them out. Will update the comments if I find anything.
@@barntech2291 that’s a little more common issue how many miles are on the 6.4?
About 170k. It sat up for three years though. That’s worse for them than racking up miles
Uneven crank. Bad cylinder?
I think fuel issues. New videos on the way!
@@barntech2291 me thinks that on these diesel's, every fuel system component should be replaced when the miles have added up. I did mine at 197,000, now the hpfp was going bad but only that one item. If we replace that fuel pump only we'd be crazy without doing the whole thing. You sir can save a huge dime doing it yourself. Thanks for posting. I re used the fuel rails and cooler, those are still good.
If you have any issues the fuel cooler will need replaced. My cooler had a bunch of glitter from the HPFP. I flushed for a long time and it kept coming.
As much as I love my truck if it gets to that point I'm not even going to pull the cab. I'll just set it on fire right there in the driveway.
Haha!
Bullet proofing kills these. I have rebuilt tuned 6.4s many times. Never have had to rebuild any stock ones. Tuning takes out bearings and the cam. If you don't get all new parts you will be plagued forever. Don't be cheap with a 6.4. They bite.
I think you trade one problem for another
@@barntech2291 Yes, you trade being on the side of the road for a sensor for being on the side of the road for a crankshaft or cam. Was your cam good? I have changed many in 6.4s because they wear through the case hardening. They wear and then start wearing the lifter roller into an egg shape. Then you get an intermittant miss.
Cam was good. Issue seems due to spun rod bearing. I have no idea how tuning could cause this, unless it raises the rev limit. I don’t think my engine ever went much above 3k rpm though. Is that what you think happened?
@@barntech2291 They advance the injection timing with the tunes. The increased pressure from the advanced timing hits hard on the top of the piston, if it doesn't crack the piston cup ( that's why you decup the pistons for high performance ) the shock force is transfered to the bearings. It will keep smashing the bearing. I see it with the center main bearing most of all. you will see a copper spot on the lower bearing from it getting pounded. The 6.4 runs perfect untill it's blown up. The 6.4 despite that is my favorite powerstroke to make power with. They just don't make it very long. This is what I see and I'm sure there are plenty of people that will dissagree
@@barntech2291 Bill Hewitt from Powerstroke help has a good video on this subject
only the pro rebuild a 6.4
Or the crazy 🤪
U better tank everything and throw clean and start over or your gone waste it again
I did a lot of cleaning off camera. I show just enough to get the gist of what I am doing. I hope anyone who goes this deep in their engine knows how to read between the lines. For everyone else it’s entertainment.
There are better hobbies than working on a 6.4 powerstroke. If it's fun for you thats all that count.
I enjoy working on engines. I do not enjoy working on my daily driver. I am working on one last video of this truck and I will move on to other projects.
Lost the lifter
I wish it was that easy! The noise was turbos but the damage was much more extensive. It turns out my fuel issues are not over either. Keep an eye out for the next (and hopefully final) video.
It's never a good sign when your vehicle reminds you of bible verses.
Or when your vehicle makes you pray…
Shame on ford for putting this engine on the road. Many people have spent good money for a diesel in faith they bought a reliable HD vehicle. So sad and again shame on ford.
It’s hard to defend Ford, because this is the most unreliable engine I have ever heard of; it breaks in more ways than I can imagine. However, please consider two facts: 1) The US EPA did not allow Ford to continue making the 7.3, and 2) No other light duty truck can match the torque of a 6.4 in its stock configuration. I love my new Dodge, but I miss the power of my old 6.4.
@@barntech2291 Blame the EPA for changing regulations so quickly during this period that Manufacturers could not design and fully test those 'air purifiers' before releasing them. These motors in Internationals larger trucks did not have all that crap and never had issues.
These engines are critical. U can’t half do them sorry
I did a lot of cleaning measuring and torquing off camera. I show just enough to get the gist of what I am doing. I hope anyone who goes this deep in their engine knows how to read between the lines. For everyone else it’s entertainment.
Boat anchor
I find it hard to believe, but I had two problems that day. What stopped me in my tracks was the HPFP (new video coming soon), but when I coasted to the side of the road my main bearings were seized. The fuel system and oil system in this engine are completely separate. What are the odds that both would catastrophically fail at the exact same time?
I can tell you exactly what that is.... It's a spun rod bearing, I admire your patience and video's but a 6.4 power joke is the biggest POS engine ever produced, just a fact, if you want to keep the truck do a Cummins swap and be done with it, 6.4 is nothing but a hole to throw money in.
As @debossgarage said, “I have never made money working on a Ford”. It’s time I move on…
That don’t sound good
Nope! It didn’t. I could not have scripted all that stuff breaking for this video.
can youdeacribe the method you used to lift the cab on the truck w blown engine. I dont have a lift but may build an A-frame to do the lift
I talk about it a little in my latest video. I used 2x10’s with 2x6’s screwed on top and bottom like an I-beam. The 2x10 in the rear of the cab cracked. I probably should have screwed two of them together with the 2x6’s on top and bottom.
He'll yeah brother let me know when you want to come to FL to work on mine jk lol
I hope yours isn’t as broken as mine!
@@barntech2291 Well, it sure won't be a stranger to you, no matter what's wrong with it!
6.4 are as bad as a 6.blow....my 2001 7.tree f2shity has 980 thousand miles all original Michigan truck works construction and plowed every winter of its life...still stroking and purrs like a kitten 😸... 13 letter shitspreader INTERNATIONAL best diesel ever made. I've been driving it for 23 years now....try that dodge Chevy or Toyota....
I don’t think this 6.4 has a million miles in it…not with 15k miles between these last two rebuilds.
No it doesn't.. international doesn't even claim engine life past 250-300 before a rebuild. And Toyota and Cummins both product million miles engines often.
How much did it cost you to build your tent Gurage. Slab and all.
It is an insulated metal building (pole barn). I had it built about 8 years ago - before COVID sent construction materials through the roof.
@@barntech2291 yeah that definitely plays a factor. I bet where I’m at that’ll be around 6 to 10k. I just built a little walk out porch with a ramp for my moms camper and that costed around 1k
*laughs in 250k 7.3 running on its own oil changes*
I have pistons from three rebuilds of this engine. The second time I nicknamed it Aftermath, but now I think Snakebit is a better name.