6.4L Complete Rebuild - Ford Powerstroke Diesel Forum
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post #1 of 12 Old 11-28-2012, 08:40 PM Thread Starter
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6.4L Complete Rebuild

hello I am new to Powerstroke.org I have always looked trough the forum but wast a register member till now so be patient, I am doing a complete rebuild of 6.4l motor for a friend of mine. I work for a gas and diesel repair shop in California we work mostly on 7.3l and 6.0l but this is going to be my first 6.4l rebuild and I wanted to post the progress of the rebuild.


The Truck
2008 Ford F250
6.4L Powerstroke
210,000 Miles

The Problem: According to the customer (in this case my friend )
he was driving on the freeway when he heard a loud explosion and alot of white smoke coming out of the tailpipe. He towed the truck to the shop. we turn on the truck and it had a knocking sound, in the beginning we thought that it was just some bad lifters. we did a tear-down and found two cracked pistons Cylinder #1 and Cylinder #8. we also notice that the turbo & pipes had alot of oil we drain the Inter-cooler and collected about 3Qts of motor oil.
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post #2 of 12 Old 11-28-2012, 08:44 PM Thread Starter
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sorry guys have to go, will post pics tomorrow.
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post #3 of 12 Old 11-28-2012, 09:02 PM
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Welcome to the forum!

What are the plans with the truck? Just an average rebuild? Deleting the dpf, EGR or just keeping it stock?

08 F350 JOB 1
H&S MINI MAXX HD300 W/S1M
SINISTER EGR/COOLER DELETE
6000K BEAMERS HID HEAD & FOGLIGHTS
KMC XD WHEELS W/NITTO TRAIL GRAPPLERS
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ROTELLA EC-1 RATED COOLANT
5" DP BACK FLO-PRO EXHAUST
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post #4 of 12 Old 11-28-2012, 09:37 PM
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Oil seal in turbo fail& hydro locked the motor!?


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99 ford f-250 crew cab powerstroke
-skyjacker 6'' lift
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-cops are in love with the thing

08 TRX700XX
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01 recon es 250
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post #5 of 12 Old 11-29-2012, 07:15 AM
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Looking forward to the progress!

08 F350 cc/sb 4X4
h&s minimaxx, 5" flo pro, 4" down pipe, no limit cold air intake, dirty diesel EGR delete with intake elbow, 6.0 exhaust manifolds, custom up pipes, ported intake manifold, Apex 71mm LP turbo, Rudy's cold side pipe, diesel site coolant and transmission filter, diesel site intercooler boots, ccv mod, bilstein shocks, gogo dd solenoid, HID lights, Airdog II 165, PMF traction bars, PMF drag link, moshimoto aluminum radiator
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post #6 of 12 Old 11-29-2012, 07:45 AM
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I don't know what the emissions laws are for that part of California, but I doubt he's deleting anything.

Good luck on the rebuild. Let us know your gameplan and we can possibly give advice here and there on what parts to pick up.


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post #7 of 12 Old 11-29-2012, 07:46 AM
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Subscribed.....I would like to know what caused the failure. Also, Welcome to the site. You will find a ton of knowledge, and a bunch of good people too.

Good Luck!

2010 Ford F-250 Super Duty, Lariet 4x4, Crew Cab Short Bed, loaded with every option...and more


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post #8 of 12 Old 12-01-2012, 06:59 PM Thread Starter
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Sorry guys been really busy will post some pic this weekend.
Like 700xxmaniac said everything was cause by a damage turbocharger.
and as to the build is just going to be a stock rebuild with head studs. Emissions laws in California are really strict and diesel have to be smog,
and yes this site has tons and tons of information thank you guys.
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post #9 of 12 Old 12-10-2012, 04:30 PM Thread Starter
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Sorry guy I havent posted an update, i had a very bad week I was in a car accident and hast been really working or online.

However today I went to the shop and I found something that blew my mind the 6.4l was in pieces and I saw this







I dont know who took the pistons out but this really piss me off.
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post #10 of 12 Old 12-10-2012, 06:51 PM Thread Starter
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I need you guy's opinion I was talking to my friend and he ask me about the pistons, from the begining i told him that we were gonna replace them. Now he doesnt he is telling me that his budget is lower and he cannot afford a new set off pistons and rods. If it was for a customer i would just said we have to but my friend wants to know if we can reuse any of the pistons.

Two of the pistons are broken and two have some dents (the ones on the pics) the other four are in good condition the only consern that I have is that they have like 200k miles. I know that you guys are thinking the samething just replace them with new ones.
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