2015-2016 Ford 6.7L Powerstroke Tools

Servicing the 2015-2016 Ford 6.7L Powerstroke

This is the second-generation 6.7L: a compacted graphite iron block with reverse-flow aluminum heads, the turbo and exhaust manifolds in the valley, a Bosch CP4.2 high-pressure pump and a Garrett GT3788V variable-geometry turbo. The charge-air cooler is air-to-water, tucked in the valley and cooled by the secondary, low-temperature coolant loop. Fuel runs from a frame-mounted conditioning module with the electric lift pump, a 10-micron primary filter and a water separator, up to a 4-micron secondary filter on the engine. The 2011-2016 service numbers are the FD-4615 fuel filter kit, FL-2124S oil filter, FA-1909 or FA-1902 air filter and FT-187 transmission filter, and the engine takes 13.0 quarts of oil with the filter. The jobs you will repeat are fuel filters, oil, coolant service on both loops, the CCV and glow plugs.

Where service goes wrong

Fuel system work is the big one. After a fuel filter change or CP4 service, the system has to be primed before the first start or the CP4 can be starved. Diesel Hub's procedure is to cycle the key to RUN 5 to 10 times for 20 to 30 seconds each, and let the lift pump run 5 to 10 seconds after the wait-to-start light goes out. Skip it and you can expect a long crank, a no-start and wear on the pump. Finding the primary filter is its own step: depending on cab and bed, it can sit ahead of, left of or right of the fuel tank. The CCV oil separator is sealed on these years and replaced as an assembly. It sits just behind the engine-mounted fuel filter, so that filter comes off first. Then you release the CCV outlet hose at the turbo inlet, remove four 10 mm bolts, lubricate the o-rings and install the new unit.

Basic tools vs. dedicated tools

A socket set and a drain pan will get an oil change done. Dedicated tools earn their place on the jobs you repeat and the jobs that are hard to undo: a socket sized for the oil filter, thread chasers to clean a hole before a bolt goes back in, and a purpose-built tool to remove track bar bushings. A boost tester is the diagnostic piece of the kit. It pressurizes the intake side through the compressor inlet so you can find a leak in the charge-air path, which on this engine runs through the air-to-water cooler in the valley. And if your truck regens often, pair oil changes with an oil analysis. Fuel dilution up to 5 percent between changes is considered normal and over 7 percent severe, and analysis is the documented way to set a safe drain interval.

What we carry

• Pacific Performance Engineering 114000759 93 mm billet aluminum oil filter socket, listed for 2011-2026 6.7L Powerstroke and 2020-2025 6.6L Duramax.
• XDP thread cleaning chasers in M8x1.25, M12x1.5, M12x1.75 and M16x2.0.
• SPE Motorsport S200115 track bar bushing removal tool and S200116 track bar bushing and removal tool kit, listed for 2005-2025 6.0L, 6.4L and 6.7L Powerstroke trucks.
• Calibrated Power Solutions Stealth Boost Tester with HD regulator, the 1102F011 compressor inlet adapter for 2011-2024 6.7L Powerstroke, and an inlet adapter for S300, S400, S400R and S500 turbos.
• Merchant Automotive 37000 quick disconnect tool kit and 10514 right-angle grease gun adapter.
• WCFab modular steel work benches in 32 x 48, 32 x 72 and 32 x 90 inch sizes.
• S&B 80-1000 flexible silicone tool tray.

Fitment notes

Most of these are shop tools that work across platforms. The truck-specific ones say so on the listing: the PPE socket for 2011-2026 6.7L engines, the SPE track bar tools for 2005-2025 Powerstroke trucks and the Calibrated Power 1102F011 adapter for 2011-2024 6.7L. The track bar tools are for the 4x4 front end, where a coil-sprung solid axle is located by radius arms and a track bar. 4x2 trucks use Twin-I-Beam, and the two front ends share no parts. Match each chaser to the thread pitch before you run it in. If you are unsure which tool fits your job, call the shop.

Frequently asked questions

How do I prime the fuel system after changing filters on a 2015 6.7L?

Cycle the key to RUN 5 to 10 times, holding each cycle 20 to 30 seconds, and let the lift pump keep running 5 to 10 seconds after the wait-to-start light goes out. That is Diesel Hub's procedure, and it keeps the CP4.2 from being starved on first start. Skipping it leads to long cranking, a no-start and pump wear.

What filter part numbers does a 2015-2016 6.7L Powerstroke use?

The 2011-2016 service numbers are FD-4615 for the fuel filter kit, FL-2124S for oil, FA-1909 or FA-1902 for air and FT-187 for the transmission filter. The engine holds 13.0 quarts of oil with the filter. The PPE 93 mm billet oil filter socket is listed for this engine.

How hard is the CCV replacement on a 2015 or 2016?

It is a bolt-in job once you can reach it. The CCV sits just behind the engine-mounted fuel filter, so remove that filter first, release the CCV outlet hose at the turbo inlet, take out four 10 mm bolts, lubricate the o-rings and install. On these years the separator is sealed and replaced as an assembly.

What does a boost tester tell me on this engine?

It pressurizes the intake side through the turbo's compressor inlet so you can find leaks in the charge-air path. On the 6.7L that path includes the air-to-water charge-air cooler in the valley. The Calibrated Power 1102F011 adapter is listed for 2011-2024 6.7L Powerstroke compressor inlets.

How often should I change oil on a truck that regens a lot?

Let oil analysis set it. Active regens post-inject fuel, and some of it ends up in the crankcase. Up to 5 percent fuel dilution between changes is considered normal and over 7 percent severe, so testing tells you whether your current interval is safe.

Not sure what fits? Call the shop at the number in the header, or use the fitment checker on any product page. We install everything we sell.