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When you own a Ford F-Series Super Duty with a 6.7 PowerStroke diesel engine, you’ve got a truck capable of more than any other. That means rugged exposure. In extreme situations, the oil pan is vulnerable, much like other trucks and SUVs. It’s not common that you need to replace your upper or lower oil pan. But for 6.7 PowerStroke-equipped F-250 to F-350s, you won’t believe what it takes to remove the upper oil pan.

How common are oil pan leaks on Powerstroke diesel engines?

Ford F-150 Powerstroke truck
2021 Ford Super Duty PowerStroke | Ford

If that’s your truck’s fate, the body must be removed to access the oil pan on 2020 to the current 6.7 Powerstroke F-250s. Ford has gone through a number of methods to seal the upper pan, and nothing seems to keep it from leaking. The first few years of 6.7 PowerStroke production use a pressed-in gasket that eventually leaks due to aging.

In 2017, Ford eliminated the gasket and instead used RTV. Oil leaks seemed to increase with these 2017 to 2019 engines. But you could still remove those pans without the body-off mess. For 2020, Ford began using a flat gasket combined with RTV, with still more leaks. This is when removing the body became mandatory according to Fordtremor.

There are two 6.7 Powerstroke oil pans, which one needs this?

2021 F-150 with PowerStroke diesel
2021 Ford Super Duty PowerStroke | Ford

The lower oil pan is no problem, and many replace it with a zoomy cast pan for a visual diesel upgrade. For decades, many mechanics have complained about how automakers just don’t have repairs in mind when designing these trucks. This is a perfect example of that mantra.

Not to sound like an old curmudgeon, but replacing an oil pan was not a big deal back in the day. Yeah, you might have to remove a cross member or lift an engine a few inches for access. But removing the entire body of a vehicle to gain access to an oil pan is kind of crazy. 

Why do 6.7 PowerStroke engines need pans removed?

F-350 powered by a 6.7 PowerStroke diesel engine
2021 Ford F-350 Super Duty PowerStroke | Ford

So, why would you need to replace an oil pan? Mostly, it is either about damage or a leaking gasket. If it is a catastrophic reason, like a spun bearing or worse, you’re going to need to yank the engine. But replacing an oil pan for any of these reasons should not require this type of time-intensive repair. 

The 6.7-liter Powerstroke V8 is a monster of an engine. It is big and bulky. Regardless, it shouldn’t require having to lift the cab off of the frame to get to it. 

Yeah, we get that real estate in the engine compartment and surrounding vicinity is limited. We’ve seen different reasons why removing the cab might be necessary. But they only indicate the situation being a band-aid for different production or component compromises. 

Removing a truck cab is a big deal

Ford F-150
2021 Ford Super Duty PowerStroke | Ford

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Removing the cab of a vehicle doesn’t mean removing a few bolts and lifting it off. There are linkages for the accelerator, brake lines, shift mechanisms, wire looms, and more. So once the body is removed, when it is time to replace it, all of these functions must be hooked back up, too.

Some PowerStroke fanboys will tell you that removing the body is no big deal. It’s a big deal. Watch the Flying Wrenches video to see for yourself. This pretty much kills any DIY dreams of fixing leaking engines without a full-on shop. Then, it’s not a big deal, but who has access to a shop like that? 

Editor’s note: Updated with model corrections