How to Bulletproof a 6.7 Power Stroke (2020 and Newer): What Fails and How We Fix It
What does "bulletproofing" mean?
Bulletproofing is a term that came out of the early diesel enthusiast community. It means fixing an engine's known weak points before they fail — replacing the factory parts that tend to break with better-designed ones. No engine is truly bulletproof; it means the failures that engine is known for have been dealt with.
Why do it before something breaks?
A failure rarely takes out just one part. One weak part failing often damages the parts around it. Fixing the first link costs far less than the chain.
You choose when the truck is down — not the side of the road with a trailer behind you.
Doing the work together saves labor. When parts are already off for one job, the next one costs less to do at the same time.
Documented work helps resale. Buyers who know these engines ask whether it's been done, and receipts answer that.
What bulletproofing isn't
Removing emissions equipment. Deletes are illegal on road vehicles under current federal law, so Westco doesn't do them. If that law changes, we'll revisit it.
On a 2020-and-newer 6.7 Power Stroke, the things that matter most are the high-pressure fuel pump (and whether Ford's fuel pump recall software has been installed), upper oil pan leaks driven partly by crankcase pressure, and emissions-system faults in the DEF, NOx sensor and DPF systems — many of which are fixed with factory software updates rather than parts. Westco handles all three in-house, including dealer-level module programming. Call Westco at (719) 591-7743.
Free Diesel Health Report ($220 value) with code PS6720. Details at the end of this article.
Which 6.7 Power Stroke years and trucks does this cover?
This covers the third-generation 6.7-liter Power Stroke V8 that Ford introduced in the 2020 Super Duty (F-250, F-350 and up). Ford gave it a new 36,000-psi fuel injection system with new injectors, a redesigned electronically actuated variable-geometry turbo, steel pistons, and a stronger block, heads, connecting rods and bearings. It's rated at 475 horsepower and 1,050 lb-ft in pickups.
For 2023, Ford added a High Output version rated at 500 horsepower and 1,200 lb-ft. It uses its own turbocharger with a water-jacketed turbine housing, upgraded cast stainless exhaust manifolds, and different tuning. The weak points below apply to both versions unless noted. Ford paired it with a new 10-speed automatic.
If your truck is a 2011–2019, see our Power Stroke service page — those engines have a different list.
Why does the high-pressure fuel pump fail on a 2020+ 6.7 Power Stroke?
Inside the high-pressure pump, the pumping elements are driven through a roller and tappet. When that roller and tappet wear, the pump sheds metal into the fuel, and that debris travels downstream into the rails and injectors. That's why a pump failure on these engines usually means replacing the whole high-pressure side, not just the pump.
What Ford changed: The 2020 engine got a new, higher-pressure fuel system, but the pump still uses a roller-and-tappet drive. In 2024 Ford recalled about 295,000 2020–2022 Super Duty and 2021–2022 F-650/F-750 trucks (NHTSA recall 24V957). Ford's own filing says aged biodiesel deposits can form on the pump's drive roller and in the tappet cooling passages, which increases wear and puts metal debris in the fuel system. Warning signs Ford lists are long cranking, a check engine light, noise and reduced power. The remedy is a PCM and TCM software update that increases cooling in the tappet area. Ford later issued a follow-up recall for some trucks where that update was done incorrectly.
That software lowers the risk on the trucks it covers. It doesn't change the fact that this pump depends on clean, dry fuel to lubricate itself. For the background on why this pump family has the reputation it does, read our CP4 pump post.
How we fix it:
Confirm the recall software is installed — Westco does dealer-level PCM and TCM programming in-house.
Fuel filters and water separator serviced on schedule, because water and dirt are what the pump can't tolerate.
If a pump has already failed, the repair is the full high-pressure system — pump, injectors, rails and lines — plus cleaning the tank and low-pressure side, so leftover metal doesn't kill the new parts.
Westco does pump conversions to a different pump design wherever conversion parts exist for your truck. Whether one makes sense depends on the truck's warranty status and how it's used; we'll talk through it with you.
Why does the upper oil pan leak on a 2020+ 6.7 Power Stroke?
The upper oil pan seals against the bottom of the block and the front cover. Oil weeps out at that joint, and leaks there are commonly reported on 2020-and-newer trucks as well as older ones. Crankcase pressure is a big part of it: if the crankcase vent (CCV) oil separator restricts flow, pressure builds and pushes oil past seals and gaskets.
What Ford changed: For the 2017–2019 trucks, Ford issued TSB 22-2201 for upper oil pan leaks. Its procedure is almost entirely about surface prep — no metal scrapers or wire wheels on the sealing faces, specific cleaners, a prep wipe, and installing the pan within minutes of applying sealant. Ford has also changed the CCV separator design several times, including on the 2020–2022 and 2023-and-newer engines. Ford hasn't published a bulletin we could find that declares the 2020-and-newer pan leak solved.
The upper pan is sandwiched between the engine and transmission, so getting it out is a big job. The transmission and a lot of surrounding parts come out of the way, and on many trucks the engine or cab has to be raised or removed for clearance. That's where the labor goes, and it's why you want it done once, correctly.
How we fix it:
Check crankcase pressure and the CCV separator first. Resealing the pan without fixing high crankcase pressure invites a repeat leak.
Confirm the leak with dye so we're not resealing a pan that's actually catching oil from somewhere else.
When the pan comes off, follow Ford's surface-prep procedure exactly — clean, oil-free sealing faces are what make the reseal last.
While it's apart, look at the rear main seal, the transmission front seal and the oil cooler area, since the labor overlaps.
Why do the DEF, NOx sensor and DPF systems throw faults on a 2020+ 6.7 Power Stroke?
These systems clean the exhaust, and when one of their sensors or modules disagrees with the others, the truck sets a check engine light and can derate. On the 2020-and-newer trucks, a lot of these faults have turned out to be software, not failed parts.
What Ford changed: Ford issued several reprogramming bulletins for 2020 trucks, including TSB 20-2044 and TSB 20-2336, covering DEF and NOx sensor codes (such as P203B and P2201) and, in the second one, a forced-idle condition. Fix: reprogram the PCM. Ford also issued Emission Recall 23E01 for certain 2022 Super Duty 6.7 trucks because the NOx sensor preheat wasn't working in the factory calibration, which could make the NOx sensor fail. The remedy was a PCM software update, no parts.
The DPF needs regular regeneration to burn off soot. Trucks that idle a lot or only make short trips may not finish regens, and Ford's TSB 21-2052 covers 2020–2021 trucks that keep trying. The fix there is a manual regen from the instrument cluster and a change in how the truck is driven. The EGR cooler and valve can also load up with soot on high-idle trucks.
Colorado Springs angle: DEF freezes in cold weather. The truck has heaters for this, but Ford's own forced-idle bulletin starts with warming the DEF tank above freezing indoors.
How we fix it:
Read every module for stored codes, then check for open bulletins and recalls before replacing any sensor.
Update module software with dealer-level programming in-house when Ford has a fix out.
Repair or replace failed NOx sensors, DEF pump/heater parts, EGR valves and coolers with correct parts.
Look at how the truck is used — a work truck that idles all day needs a different maintenance plan than a highway tow rig.
Repair, never delete.
Does the 10-speed transmission have a known issue?
Ford's TSB 26-2088 covers 2020–2022 Super Duty trucks built on or before Dec. 13, 2021 with harsh reverse-to-drive engagement and no codes. Ford points to sticking valves in the main control valve body and/or damaged input and output shaft seals. The first step is a series of relearn routines; if that doesn't fix it, the transmission comes out to replace the seals. Ford also issued TSB 23-2082 for 2020–2022 trucks that needed both PCM and TCM reprogramming. Westco does the relearns and programming in-house.
What should you check before buying a used 2020+ 6.7 Power Stroke?
Visible checks
Oil wetness along the oil pan rail where it meets the block and front cover.
Exhaust intact, with the DPF and SCR system in place. A deleted truck may fail emissions and can cause registration and resale problems.
DEF that looks clear, and no sign anyone put DEF in the fuel tank — that contaminates the entire fuel system.
On the test drive
Cold start: long cranking is one of Ford's listed warning signs for the fuel pump.
Smooth power under load. On a grade like Monument Hill or Ute Pass with weight behind it, watch for derates or warning messages.
Reverse-to-drive engagement and smooth shifts through the 10-speed.
With a scan tool
Stored and pending codes in every module, especially fuel pressure, DEF, NOx and DPF codes.
Recall status: run the VIN for recall 24V957 and, on 2022s, emission recall 23E01.
Regen history and soot load, if available.
Our Power Stroke buyer's guide and pre-purchase inspection cover the rest.
What in the service records shows it's already been done?
The fuel pump recall software (24V957, and the follow-up if it applies) shown as completed.
Fuel filter changes on schedule.
A CCV separator replacement or crankcase pressure check.
Any upper oil pan reseal, with the Ford procedure noted and the CCV addressed at the same time.
Module reprogramming tied to specific bulletins or recalls.
Emissions repairs done as repairs, not deletes.
Is my 2020+ 6.7 Power Stroke still under warranty?
Possibly. Ford's diesel engine coverage runs five years or 100,000 miles from the warranty start date, whichever comes first, so many 2022-and-newer trucks may still be inside it, and recall remedies are free to the owner regardless. Plenty of owners also carry an extended service plan. Westco works with all extended warranty companies and handles the claim for you — see our extended warranty claims page.
Get a free Diesel Health Report on your 6.7 (code PS6720)
We'd like to be your diesel shop. Here's how we'd like to earn it.
Mention code PS6720 and get a complete Diesel Health Report on your 6.7, a $220 value, free. We give it a bumper-to-bumper visual inspection, pull the live data that matters on this engine, run the full set of key-on engine-off and key-on engine-running tests, and photograph what we find. You get a detailed digital report to keep, so you know exactly where your truck stands today.
This is a paid inspection, and our technician is paid to do it right. With your code, it's free to you. No repair to buy, no catch.
Why give it away? Because we'd rather show you how we work than tell you. Our mission is to apply all of our knowledge, skills and experience to take care of your truck, and to have you leave feeling you were treated fairly and professionally. Most of all, we want you to enjoy doing business with the WESTCO family. If the report earns your trust, we hope you'll make us your shop.
What your Diesel Health Report checks on a 6.7
Fuel pump recall status. We check whether the 24V957 software (and the follow-up, if it applies) has been installed, and run a full module scan.
Low-side fuel pressure. Ford's own figures put normal supply pressure around 4.5 bar (about 65 psi), and the high-pressure pump needs at least about 3.5 to 3.7 bar (about 51 to 54 psi). Below that, the truck shows a low fuel pressure message and sets a code. Readings near the low end are worth a closer look at the filters and supply side.
Fuel rail pressure, desired vs. actual. We compare what the computer asks for with what the pump delivers. A gap between them is worth a closer look.
Upper oil pan and crankcase vent. We look for oil weeping at the pan joint and check the crankcase vent (CCV) separator.
DPF soot load, regen history, and DEF and NOx data. Many faults on these trucks are software, so we check the data and any open bulletins.
Visual. Coolant level and lines, the 10-speed for leaks, and leaks bumper to bumper.
Normal readings vary by year, calibration and scan tool. Your report shows where your truck sits and what's worth watching.
Health report or diagnostic?
The Diesel Health Report is a checkup for a truck that's running fine. If yours is running rough, smoking, down on power or showing a code, it needs a diagnostic instead. Call us and we'll get it in.
How to redeem it
Call (719) 591-7743 and mention code PS6720, or
Book online and type PS6720 in the "What does your vehicle need?" box.
New and returning customers, one per truck. Good through January 31, 2027.
Other Power Stroke generations
Bring it to Westco
Westco does fuel system, oil leak, emissions and programming work on the 2020-and-newer 6.7 Power Stroke in-house, and backs our work with a 24-month/24,000-mile parts and labor warranty. Lyft valet drop-off is available if you book 24 hours ahead.
Book my FREE Inspection or call (719) 591-7743.
Comments