Best Upgrades for the 2011-2016 6.7 Powerstroke
The first-generation 6.7L Powerstroke put Ford back on top of the diesel game in 2011. More than a decade later, plenty of these trucks are still towing, hauling, and racking up miles every day.
But age and mileage have a way of exposing factory weak points, and the 2011-2016 trucks have a few that are well known among owners. Some carry over to newer trucks. Others, like the original turbocharger on 2011-2014 models, are specific to these early years.
The best upgrades for the 2011-2016 Ford 6.7L Powerstroke focus on reliability, protecting expensive components, and fixing known factory weak points before they leave you stranded.
In This Guide
- S&S Gen2.1 Disaster Prevention Kit – protect the fuel system from CP4 failure
- Upgraded Turbocharger – replace the problem 2011-2014 turbo
- Cold Side Intercooler Pipe – ditch the factory plastic pipe
- S&S Fuel Leak Prevention Kit – replace crack-prone plastic
- Edge Insight CTS3 Monitor – see what your truck is doing
- Which upgrades to do first
1S&S Diesel Gen2.1 Disaster Prevention Kit
Every 2011-2016 6.7L Powerstroke left the factory with the CP4 high-pressure fuel pump, and it has been a concern among owners for years. When a CP4 fails internally, it can send metal debris throughout the fuel system, contaminating the injectors, fuel rails, lines, and even the tank. What starts as a single failed pump can quickly turn into a repair bill well into the thousands.
The S&S Gen2.1 kit is designed to redirect and capture that contamination before it reaches other expensive components. It features a 9-micron return filter with a clear bowl for easy inspection, plus OEM-style quick-connect fuel lines, so there's no cutting the factory supply line during installation.
Why we recommend it
- Helps protect injectors, fuel rails, lines, and tank from CP4 failure debris
- Can significantly reduce the damage caused by a failed CP4 pump
- Inspectable 9-micron return fuel filter
- OEM-style quick-connect fittings for a cleaner install
- Added protection without replacing the factory high-pressure pump
2Upgraded Turbocharger (2011-2014)
If you own a 2011-2014 6.7L Powerstroke, the turbocharger deserves a spot near the top of your list.
These trucks came with the Garrett DualBoost turbo, an innovative design for its time, with a ball bearing system and the industry's first double-sided compressor wheel. It also earned a reputation as one of the most problematic parts on early 6.7L trucks, and the oldest ones are now the furthest along in age and mileage.
For 2015, Ford switched to a larger, more reliable Garrett GT37 VGT turbo. That turbo is the starting point for Rudy's in-house retrofit kits, which let 2011-2014 owners move to a more dependable setup with added performance.
Rudy's · Fits 2011-2014
Rudy's Upgraded Turbocharger Retrofit Kits
- Replaces the problematic OEM 2011-2014 VGT turbo
- Built on the more reliable 2015-2016 Garrett GT37
- Water-cooled, journal-bearing center section
- Works with all emissions components in place
- Includes down pipe, lower intake manifold, oil and water lines, gaskets, and seals
- Reuses your existing intercooler piping and air filter
Choose your compressor wheel below.
Rudy's · 62.5mm Billet
62.5mm Billet Turbo Retrofit Kit. Added airflow with a billet wheel.
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Rudy's · 65.5mm Billet
65.5mm Billet Turbo Retrofit Kit. The largest wheel option for more power.
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Want to stay stock?
If your 2011-2014 pickup's turbo has already failed and you'd rather keep the factory setup, we also carry the Garrett stock replacement turbo.
Own a 2015-2016?
Your truck already has the GT37. If you want more performance, the KC Turbos Jetfire fits with a 17-19 pedestal conversion kit.
Why we recommend it
- Replaces a turbo with a known reputation for problems on 2011-2014 trucks
- Upgrades to a more durable, journal-bearing GT37 platform
- Adds performance while keeping strong towing capability
- Keeps your emissions equipment in place
- Complete kit with the parts needed for the swap
3Upgraded Cold Side Intercooler Pipe
If there's one part on the 2011-2016 6.7L Powerstroke with a reputation for leaving owners stranded, it's the factory plastic cold side intercooler pipe and boot.
Constant heat cycles and boost pressure take their toll, and the plastic pipe and boot are known to crack, burst, or blow apart. When that happens, the truck suddenly loses boost and power, which is especially frustrating when you're pulling a trailer far from replacement parts.
Replacing the plastic pipe with metal is one of the most affordable reliability upgrades you can make. Rudy's own cold side kit uses mandrel-bent aluminum, a CNC-machined quick-disconnect coupling, silicone boots, and constant-tension T-bolt clamps. It also removes restrictive bends from the factory pipe for better airflow, and no tuning is required.
Recommended options
4S&S Diesel Fuel Leak Prevention Kit
Another often-overlooked weak point is the factory fuel filter housing and its plastic fuel connections.
Repeated heat cycles, vibration, and routine maintenance take a toll. On a truck that's been on the road for a decade or more, the plastic engine-mounted fuel filter housing and injector return fitting can become brittle and crack, leading to diesel leaks.
The S&S kit replaces the factory plastic housing with a precision-machined billet aluminum housing and swaps the brittle OEM injector return fitting for an aluminum Fuel Leak Prevention Fitting. It also includes a Donaldson spin-on fuel filter rated at 4-micron absolute filtration at 99% efficiency, with nearly double the dirt-holding capacity of the factory filter.
Better yet, it works with the factory fuel system and the S&S Disaster Prevention Kit above, making the two a great combination.
Why we recommend it
- Replaces the crack-prone plastic fuel filter housing with billet aluminum
- Upgrades the fragile OEM injector return fitting to aluminum
- Helps reduce the risk of fuel leaks and potential fire hazards
- Donaldson spin-on filter with better filtration and dirt-holding capacity
- Compatible with factory fuel systems and S&S Disaster Prevention Kits
5Edge Products Insight CTS3 Digital Monitor
Your factory dash only shows a fraction of the data your truck's sensors collect. The Insight CTS3 plugs into the OBDII port and lets you monitor parameters like exhaust gas temperatures, transmission temperatures, and boost pressure, depending on vehicle support.
On an older truck, that visibility is especially valuable. It helps you catch problems early, and if you've just upgraded your turbo, it's an easy way to keep an eye on boost and temperatures while towing. It also offers a customizable touchscreen, diagnostic trouble code functions, and configurable alerts, with no changes to your engine calibration required.
Why we recommend it
- View multiple supported engine and transmission parameters
- Monitor boost and temperatures after a turbo upgrade
- Read and clear supported diagnostic trouble codes
- Customize the display to show what you care about
- Useful monitoring without performance tuning
Which 2011-2016 6.7L Powerstroke Upgrades Should You Do First?
Working with a limited budget? You don't need to tackle everything at once. We'd prioritize based on how severe the factory failure each upgrade addresses:
Protect the expensive fuel system components a CP4 failure can destroy.
Replace the problematic early turbo with a more reliable GT37-based retrofit.
An affordable fix for the plastic pipe that can blow off and leave you stranded.
Replace vulnerable factory plastic fuel components to help prevent leaks and fire hazards.
These upgrades aren't about turning your truck into a race truck. They're about keeping a proven diesel dependable for years to come, whether it's a daily driver, a dedicated tow rig, or a work truck you rely on to make a living.
Final Thoughts
The 2011-2016 Ford 6.7L Powerstroke is still a capable platform, but its age means known weak points are more likely to show up. Taking care of them before they fail can save you money, downtime, and a whole lot of frustration down the road.
Whether you want to protect your CP4 fuel system, replace a failure-prone early turbo, swap out the factory plastic intercooler pipe, prevent fuel leaks, or keep a closer eye on engine temps, these upgrades are worth considering.
More guides: 2017-2022 6.7 Powerstroke upgrades · 2023-2027 6.7 Powerstroke upgrades
Upgrade Your 2011-2016 6.7L Powerstroke
We carry parts from S&S Diesel Motorsport, H&S Motorsports, KC Turbos, SPE Motorsport, Edge Products, and our own in-house Rudy's line.
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