What is the horsepower limit of a stock Power Stroke?
If you’re looking to more than double the horsepower your Power Stroke brings to the table, we’ve got you covered. If you’ve ever asked yourself much hp can a 7.3 (or a 6.0l, 6.4l, or 6.7l) Power Stroke handle? What exactly is the 6.4l Power Stroke max HP before it breaks? We’ll answer that here. First and foremost, we have to be clear: Any knowledgeable diesel enthusiast will tell you it’s not any one certain horsepower number that kills factory connecting rods; it’s the engine’s overall setup—and that is correct. Things like injection timing, EGT, oiling capability at high rpm, boost, drive pressure, and how much low-end torque you’re dealing with all dictate how long (or short) a stock rod engine will live at higher horsepower.
Sure, some engines survive higher horsepower just fine. But then, 100-percent stock engines let loose for no apparent reason once in a great while, too. So, for the purpose of this article, we’re basing our estimates off of what we’ve seen over the years throughout the diesel industry, and when (as a general rule of thumb) you can consider yourself near the breaking point. Stay tuned for installments on the horsepower limits of Duramax and Cummins mills in the months ahead…
7.3L Power Stroke:
When it comes to the 7.3 Power Stroke max hp limit, it’s the rods, and the weakest rods found in a Power Stroke engine, we have to start with the first mill offered: the 7.3L. But it’s not nearly as bad as it used to be. Over the last decade, we’ve seen improvements in leaps and bounds in the 7.3L aftermarket. Thanks to hybrid injectors, more refined tuning, and better turbocharger technology, you no longer need a built engine to have a 500-plus hp ’94.5-’03 Ford.
DANGER ZONE (forged rods): 600-650-rwhp
DANGER ZONE (powdered metal): 500-rwhp
“I get asked all the time how my forged rod 7.3L is still together, but people forget that I did (eventually) bend the number 8 rod in the original engine, so anything can happen.” —Matt Maier of Irate Diesel Performance
So when planning of doing a 7.3 Power Stroke horsepower increase, there were two types of rods offered in the 7.3L, forged steel and powdered metal, which makes all the difference in the world when it comes to how far you should attempt to push things. If you own a ’94.5 to ’99 7.3L Power Stroke, you’re in the clear, as all of those engines feature forged rods. However, powdered metal rods—known to be considerably weaker—began to make their way into production on late ’00 build date engines (starting with serial number 1425747). However, to run out its stock of forged rods, they were installed once more beginning with serial number 1440713 and going to 1498318. From there on out, powdered metal units got the nod, meaning most ’01 to ’03 model year engines have them.
As for forged rod engines, 600 to 650-rwhp is the general consensus, as long as spot-on, well-tailored PCM calibrating is behind it. This means a progressive ramp up in injection timing through the low rpm range so as not to “over torque” the engine. Stock rods are at their most vulnerable at low engine speeds (2,500 rpm or less) when cylinder pressure and torque is high, so pouring on the fuel at higher rpm keeps the rods out of danger. The one trade-off is that the torque number won’t be huge (say 1,000 lb-ft. made at 2,600 rpm on a 600-rwhp setup, as opposed to 1,200 lb-ft. being made at 2,000 lb-ft.). The same tuning methodology applies with powdered metal rod engines, but enthusiasts are highly advised to draw the line at the 500-rwhp mark.
6.0L Power Stroke:
Going beyond the fact that a lack of fasteners in the block led to the inevitable head gasket failures plaguing the 6.0L engine (or the lack of head bolt diameter, or the torque-to-yield head bolts, etc.), it is one heck of a tough engine. Hard-part wise, it’s tough to beat, especially when you consider the rods found in the LB7 and LLY Duramax engines of the same era became a problem around the 600-hp mark, if not sooner.
SIDE BAR/PULL QUOTE
DANGER ZONE: 800-rwhp
“Going beyond the fact that a lack of fasteners in the block led to the inevitable head gasket failures plaguing the 6.0L (or the lack of sufficient head bolt diameter, torque-to-yield head bolts, etc.), it is one heck of a tough engine.”
Like the late 7.3L rod, the 6.0L comes with powdered metal rods, but its rods have proven capable of handling much more power. And thanks to the utilization of a bedplate, the bottom end is extremely rigid, and the main caps don’t walk around under big horsepower and torque like they do on the 7.3L. In our opinion, the short block side of a 6.0L is a great starting point for adding horsepower.
The 6.0L Power Stroke’s small bore, four-valve design lends itself to the higher rpm range, which means peak torque is achieved higher as well. This keeps the rev-happy 365-ci mill relatively clear of excessive cylinder pressure and big torque down low—provided appropriate custom tuning is being employed. Even a decade ago, before PCM tuning was anywhere near as refined as it is now, several 6.0L owners proved the 6.0L’s bottom end could withstand 700-rwhp. Today, a lot of serious enthusiasts conclude that the 800 hp 6.0 Power Stroke range gets you into unchartered waters with a 6.0L.
6.4L Power Stroke:
In the early days of the 6.4L’s production run, no one knew how well this sequential turbocharged mill would respond to power adders, nor how durable it would be at elevated horsepower and torque levels. But once enthusiasts discovered how far you could push them, high horsepower builds sprang up everywhere. To this day, the bottom end on the 6.4L continues to impress us with its ability to handle four-digit horsepower. We’ve seen a slew of ‘08-’10 Fords make north of 900-rwhp on the factory rotating assembly. We’ve also witnessed our fair share of trucks churn out well over 1,000-rwhp, run 10s in the quarter-mile, and live to fight another day.
DANGER ZONE: 1,000+ rwhp
“I had stock pistons in my 6.4L for 60,000 miles with five different setups—from stock turbos with a wastegate and spray to big compounds with added fuel—and never had any piston issues.” —Mike Corsilli of Maryland Performance Diesel(Video) 1,500 HP 7.3L Powerstroke Engine
The weakest link on the 6.4L’s bottom end seems to be the pistons, but it’s not as cut and dry as you might think. While some crack under extreme power conditions, most failures occur due to age, and it can even happen on stock or “tune-only” trucks. From what we’ve gathered after speaking to multiple high-end 6.4L shops across the country, is that it’s a toss up on whether a stock piston will let go due to high horsepower or simply due to age or abuse.
Some gurus believe that piston failures happen more often on trucks that still utilize the factory compound turbo arrangement. The multiplication of quick spool up (lots of low-end torque), aggressive tuning, high drive pressure, and the factory piston’s design can all contribute to its failure. To some extent we agree with this theory, based on what we’ve seen, and the fact that large single turbo 6.4L’s tend to survive higher horsepower for longer periods of time.
6.7L Power Stroke:
While Ford’s initial plans for the 6.7L Power Stroke entailed the engine getting forged connecting rods, powdered metal units ended up getting the nod (most likely to keep production costs down). It’s clear that lightening up the rotating assembly was one of Ford’s goals with this engine, as the rods are considerably smaller than what was used in the 6.4L (not to mention also being smaller than 6.0L rods).
DANGER ZONE: 700-rwhp
“We advise 6.7L customers going over 700 hp that they are in the danger zone, as we’ve seen two motors let go between 725-750 hp.” —Mike Dillehay of No Limit Diesel
The add-a-turbo craze, which is an affordable way to have compound turbos under the hood on Duramax and Cummins powered trucks, was not lost on the 6.7L-powered Ford crowd. However, this is where rod failures began to surface on ’11-’14 Super Duty’s. The single sequential, dual inducer Garrett turbo proved to be a major restriction in making more power. Soon after S400 framed turbos were being installed in front of the stock charger in the valley, extreme drive pressure was present and a host of engines bent rods in or around the 600-rwhp mark.
This problem was alleviated once a freer flowing valley charger was utilized and tuning became more and more refined. Now, with the right custom tuning, a second high-pressure fuel pump, and a turbo(s) that doesn’t produce a ton of excess drive pressure, so what’s the max hp a 6.7l Power Stroke can handle, well the stock rods can easily handle 650 to 700-rwhp.DW
Thanks to great R&D work among the premier tuning companies in the industry, the 6.7L’s stock rods are holding up well currently. However, if you’re thinking about bridging the 700-hp range with your Super Duty, you may want to consider a set of Carrillo’s H-beam connecting rods for piece of mind. These rods were released very early on after the ’11 trucks debuted. We think Carrillo probably knew the lighter smaller rods in the 6.7L might not be enough for power hungry owners.Sources:
Irate Diesel Performance
Maryland Performance Diesel
Midwest Diesel & Auto
No Limit Diesel
The 7.3 Powerstroke is a two-valve behemoth which measures in at 444 cubic inches and has a maximum stock power rating of 275hp and 525lb. ft. of torque.How much HP can a stock 6.7 Powerstroke hold? ›
By and large, the general consensus is a maximum of roughly 700-rwhp on the 6.7L Power Stroke.How much HP can a stock 6.0 Powerstroke handle? ›
In fact, the 6.0L's block, rotating assembly and cylinder heads can support roughly 700rwhp in stock form.How much power can stock 6.7 Powerstroke make? ›
BorgWarner's S300 frame, and fixed geometry turbos are right at home on a 6.7L Power Stroke. Sized between 63mm and 69mm, they can support 625 to 700 hp and are very drivable.How much HP can a CP4 handle? ›
Roadblock #2: The CP4.
The Bosch piezo injectors used in all 6.7L Power Stroke engines are quick-firing and capable of supporting big horsepower (700+ rwhp).
When pushed to its absolute limit, the OEM fuel system on the 6.7L Cummins (lift pump, CP3, injectors) can support as much as 530rwhp and roughly 550rwhp with a turbo upgrade.What is the highest HP Powerstroke? ›
1. Aaron Rudolf: 1,987 HP/3,005 LB-FT.Does a 6.0 need to be bulletproofed? ›
Again, a 6.0L is not a "Bullet Proof Diesel" engine unless four of the five pattern failures are addressed with genuine Bullet Proof Diesel parts. This includes the problematic OEM oil cooler as well as the FICM module, EGR cooler and water pump.How long will a stock 6.0 Powerstroke last? ›
With proper maintenance, regular use and EGR system and oil cooler remedies, a 6.0L Power Stroke can be made to blow past the 300,000-mile mark with few, if any issues. The engine might need an injector or two along the way, or an EGR valve, but it can done.How much HP can a stock 7.3 handle? ›
The 7.3 Powerstroke is a two-valve behemoth which measures in at 444 cubic inches and has a maximum stock power rating of 275hp and 525lb.
After years of production, the 6.7L Power Stroke has proven it can storm past the 200,000-mile mark with few repairs. Provided you adhere to Ford's recommended service intervals, there is no reason this engine won't see 300,000 or even 400,000 miles.How much HP does a tuned 6.7 Powerstroke have? ›
Untouched engine, no fuel system mods, aftermarket lift pump or turbo upgrade. Simply enjoy your 540hp/1,100 lb-ft tuning, which will be refined enough to drive like stock—allowing you to carry on with your day-to-day towing chores.Why is the 6.7 Powerstroke so quiet? ›
-- Aluminum cylinder heads with inward-facing exhaust ports reduce noise. -- A single, sequential turbocharger with twin impellers delivers performance at low and high engine speeds, reducing turbo lag. The turbocharger, made by Honeywell, is mounted in the "V" between the cylinder heads.At what mileage does a CP4 fail? ›
The result is the formation of air bubbles inside the CP4. Air in the pump means that metal rubs against metal, causing accelerated wear. This will eventually cause the CP4 to fail, often around 100,000 miles.How much does CP4 failure cost? ›
As you may have already guessed, the cost of a CP4. 2 failure can be expensive. Repairs can range from $6,000 to $10,000 depending on what is replaced (vs. cleaned and reused) and who handles the work.Can you make 1000hp on pump gas? ›
See all 18 photos18 photos Breaking down the numbers, the NRE 388 makes 2.57 hp/ci on pump gas for a grand total of 1,000 hp. This is accomplished with 15 psi of boost and 91 octane. Most are well versed in the performance capabilities of Nelson Racing Engines (NRE).How much HP can a 6.4 Powerstroke handle? ›
The Heads Can Support 900rwhp
If you were wondering if the horsepower wall for the cylinder heads was around 700rwhp, you'd be wrong. The 6.4L's factory 4-valve heads can support as much as 900rwhp.
|Engine:||Ford Motor Company 6.7L Power Stroke diesel V-8|
|Peak Horsepower:||2020 - 2023 Standard Output||475 hp @ 2,800 rpm|
|2023 High Output||500 hp @ 2,800 rpm|
|Peak Torque:||2020 - 2023 Standard Output||1,050 lb-ft @ 1,800 rpm|
|2023 High Output||1,200 lb-ft @ 1,800 rpm|
The Cummins 6.7L Turbo Diesel is the most powerful engine option for RAM 2500 and 3500 pickup trucks. Producing up to 400 horsepower and 1,000 pound-feet of clean diesel torque, this powerhouse helps RAM deliver best-in-class towing.Can a 7.3 Power Stroke make 1000hp? ›
Proving the 7.3L's HEUI injection system can still run with the best of them. In the last year, each generation of the Power Stroke diesel has surpassed the 1,000hp mark on the dyno. In May 2009, the first Power Stroke to hit 1,000 hp was a 6.0L.
Jelich's 6.19 at nearly 113 mph not only makes his four-wheel drive F-350 the quickest 1/8th mile Power Stroke in existence, but it means the truck is capable of running 9.70's in the quarter-mile (at 140-plus mph).Which Power Stroke is the fastest? ›
A 2020 Ford F-250 Super Duty sped to 60 mph in 6.1 seconds, making it the quickest diesel pickup we've ever tested. The Ford's record run comes courtesy of its Power Stroke 6.7-liter turbo-diesel V-8, and it's the only three-quarter-ton truck with over 1000 pound-feet of torque.What year of 6.0 Powerstroke to avoid? ›
If you're a diesel nut like me, you probably know that most people will steer clear of buying a 2003 to 2007 model year Ford Superduty Diesel truck. The 6.0L Powerstroke is known for having major problems. Most of these problems originate from the factory design.How do you fully bulletproof a 6.0 Powerstroke? ›
- Bypass Oil Filtration. Professional Installation Packs.
- Cooling System Upgrades.
- Titanium Hardware. Fuel System Upgrades.
How Much Does It Cost to Bulletproof a Diesel? If you have the work done professionally with bulletproofed parts, you're going to pay in the range of $3,000 to $4,000 for parts and installation. It's really a small price to pay for what those particular parts will do to protect your engine's longevity.How long should I let my 6.0 Powerstroke warm up? ›
As a general rule of thumb, if it is below zero degrees Fahrenheit, you should allow your engine up to seven minutes to warm up. If the temperature is between zero and fifty degrees, the warm-up period should be three to five minutes. Over fifty degrees will only require one or two minutes to warm up.How long do 6.0 injectors last? ›
How long do injectors last? With proper care and maintenance of the engine, you can expect a diesel injector to last between 200,000 and 300,000 kilometres.Is 7.3 or 6.0 Power Stroke better? ›
The 6.0L fuel injector operates similarly to the 7.3L unit, but the valve that allows high pressure oil to enter the injector body is referred to as a spool valve. Tighter tolerances, and a more technologically advanced injection system, allow the 6.0L Power Stroke to produce higher injection pressures (3,600 psi vs.How much hp is 7.3 Godzilla? ›
|Max power @ RPM||430 hp @ 5,500 rpm|
|Ford Godzilla 7.3L Engine Performance Specs|
|Horsepower (Stock)||430 hp at 5,500 rpm|
|Torque (Stock)||475 lb.-ft. at 4,050 rpm|
"A 6.7 Powerstroke EGR delete pipe can recover up to 20% more horsepower and torque than stock Ford 6.7 diesel truck parts. Using the turbo kit will result in better acceleration and an overall improvement in fuel economy as well.Which powerstroke to avoid? ›
Ford Diesel Engine Facts
Yes, even though it's an older model, the 7.3l power stroke is still a powerful and reliable diesel engine. However, it's best to avoid the years 2001-2003 because the PSMs and camshaft position sensors often fail.
7.3s are loud for a few reasons, most of which have to do with injection systems and block material/construction. The 7.3 uses a HEUI injection system, which uses high pressure oil to create final injection pressures within each injector individually.How much boost can a stock 7.3 handle? ›
'94.5-'99 7.3L: 380 to 400rwhp
Either charger can hold up to 30-35 psi of boost for a while, but 40 psi or more is asking a lot for a turbo that was originally intended to see a maximum of 17 to 23 psi.
For context, the stock turbo size on a 6.6-liter LML Duramax is 61mm, and a 6.7-liter Cummins uses 60mm turbo. The 6.7 Powerstroke from 2011 to 2014 used a much smaller 43mm turbo, but because it used a double-sided compressor wheel, it could move a comparable amount of air to a 60mm conventional turbo.What is the nickname for the 6.7 Powerstroke? ›
The 6.7L Powerstroke was introduced in 2011. Pre-release it was nicknamed "The Scorpion". It's rumored that its nickname was due to the unique turbocharger location and intake/exhaust arrangement.How can I make my 6.7 Powerstroke faster? ›
- Exhaust Upgrades. ...
- Adding Custom Tuning. ...
- Improving the Intake. ...
- Upgrading the Intercooler Pipe.
Answer: The clatter results from the combustion of diesel fuel inside the engine. In a diesel, the fuel is ignited by high pressure and temperature inside the cylinder, rather than by a spark plug. The clatter is the result of fuel not burning as evenly as in a gasoline engine, creating a knock.What is the ticking noise 6.7 Powerstroke? ›
Description. Some Ford 6.7L Powerstroke diesel equipped vehicles may exhibit a ticking noise at idle after an engine oil change. It is often referred to as Typewriter Noise because of its similarity to the sound of random typing on a mechanical typewriter.How can CP4 failure be prevented? ›
Prevent Failures & Prolong the Life of Your CP4 Pump
Always change fuel filters regularly. It is recommended that fuel filters be changed every 5000 miles despite the manufacturers recommendations. We recommend only using OE filters with CP4 Pumps.
What makes and models are affected? 2011-present year Ford Super Duty trucks equipped with 6.7L “Power Stroke” diesel engines may have the manufacturing defect noted in the Ford CP4 Lawsuit.How do you prevent CP4 failure on a 6.7 Powerstroke? ›
What can I Do to Prevent CP4 Failure: A couple of things to note here, as I said before change your fuel filters every 10-15,000 miles with Ford Brand Filters. Install an EPA Compliant CP4 Disaster Kit (Highly recommend the one from S&S Diesel). This will save your injectors, lines & rails from contamination.What years did the CP4 pump fail? ›
GM discontinued use of the CP4 altogether after the 2016 model year, after seeing scores of CP4 fuel injection pump failures. "We commend the Court's thorough and well-reasoned analysis. It is clear that the CP4 fuel pump cannot work properly in U.S. vehicles.What happens when CP4 goes out? ›
Since the CP4 uses fuel as a lubricant, the lack of adequate lubrication can increase the amount of friction on the internal metal parts such as the drive cam and roller lifters. As a result, small metal particles or shavings begin to get distributed throughout the fuel system and can end in catastrophic failure.What does a CP4 bypass kit do? ›
1 6.7L Power Stroke CP4 Bypass Kit features all quick connect lines that will eliminate the need for cutting the factory supply line, which is a debris introduction point, especially if the cut is not thoroughly deburred. It also eliminates the need to use a compression fitting, which is a potential leak point.What fuel pump do I need for 500hp? ›
|Fuel Pump Free Flow||Carbureted Engine||Carbureted w/ Power Adder|
|30 gph/114 lph||350 hp||300 hp|
|40 gph/155 lph||450 hp||400 hp|
|50 gph/190 lph||600 hp||500 hp|
|67 gph/255 lph||750 hp||650 hp|
Premium gas has a higher resistance to engine knock in luxury and performance vehicles with turbochargers or high-compression engines, so you can hit that horsepower smoothly. Additionally, premium gas can increase fuel efficiency, potentially bringing better gas mileage for longer while decreasing emissions.How much HP for 3000 psi? ›
For instance, in order for a gas-powered pump to put out 3,000 PSI and 4 GPM, the engine needs to have at least 11 horsepower.
The factory 2011 to 2016 6.7L Powerstroke are rated at 390 to 440 rear wheel horsepower depending on the year of the vehicle.How long will a stock 6.7 Powerstroke last? ›
After years of production, the 6.7L Power Stroke has proven it can storm past the 200,000-mile mark with few repairs. Provided you adhere to Ford's recommended service intervals, there is no reason this engine won't see 300,000 or even 400,000 miles.
5.5 seconds later Charlie Fish broke the record for the. fastest 6.0 Powerstroke in the world!What size is the stock turbo on a 6.7 Power Stroke? ›
For context, the stock turbo size on a 6.6-liter LML Duramax is 61mm, and a 6.7-liter Cummins uses 60mm turbo. The 6.7 Powerstroke from 2011 to 2014 used a much smaller 43mm turbo, but because it used a double-sided compressor wheel, it could move a comparable amount of air to a 60mm conventional turbo.How much HP can stock 7.3 handle? ›
The 7.3 Powerstroke is a two-valve behemoth which measures in at 444 cubic inches and has a maximum stock power rating of 275hp and 525lb.Is the 6.7 Powerstroke better than the 6.7 Cummins? ›
The mileage of the Powerstroke engine is poorer because it struggles with carrying heavy loads over a long period or distance. The reverse is the case for the 6.7 Cummins engine, and it also has a better fuel economy when carry heavy loads.
The 6.7 Powerstroke can provide you with 30 MPG on the highway and 22 MPG in the city. Combined, the engine has a fuel mileage of about 25 MPG.How do I get more boost on my 6.7 Powerstroke? ›
- Exhaust Upgrades. ...
- Adding Custom Tuning. ...
- Improving the Intake. ...
- Upgrading the Intercooler Pipe.