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Introduced in 2011, Ford’s proprietary 6.7L Powerstroke diesel platform forever changed the heavy-duty landscape. Boasting incredible torque and lightning-fast turbo spooling, it quickly became a favorite for hotshot haulers, daily commuters, and construction crews alike. But as these trucks age and stack up heavy engine hours, serious mechanical vulnerabilities begin to show up. From sudden spun bearings to catastrophic timing failures, when a stock 6.7L fails, it fails hard.

At Choate Engineering Performance, we look at engine failure a bit differently. We don't just see broken components; we see an opportunity to re-engineer out the factory design flaws. A replacement engine shouldn't just reset the clock on your truck; it should upgrade it. Here is a look behind the curtain at what we do to fix the 6.7L Powerstroke block and make it truly "Ford Tough."

The Core Flaws: What Ford Got Wrong (And How We Fix It)

When you buy a factory replacement engine from a dealer or a cheap mass-production rebuilder, you are getting the exact same engineering errors that caused your original engine to fail. At Choate, we eliminate these issues right on our machine shop floor:

• The Spun Bearing Solution: Factory 6.7L engines are notorious for tight, inconsistent main and rod bearing clearances, leading directly to starved oil flow and spun bearings under high stress. We CNC blueprint line-hone every single block back to absolute crankshaft centerline, adjusting clearances perfectly and upgrading to high-stress HX performance bearings designed to take massive loads.
• The TIG-Welded Crank Gear: From the factory, the crankshaft timing gear is held in place by a simple interference fit. If a high-pressure component like a CP4 fuel pump locks up, it sends a shockwave down through the engine that spins that gear, throwing off the engine timing instantly and bending all 32 pushrods. We TIG-weld the crank gear permanently into place on every build to neutralize this failure completely.
• Upgraded Exhaust Valves: Stock exhaust valves are prone to high-heat separation, meaning the head of the valve breaks off from the stem, drops into the cylinder, and causes absolute engine destruction. We throw those away and install all-new, custom-alloy upgraded material valves that completely eliminate heat separation.
• Proprietary Cam Tunnel Alignment: When cam tunnels distort over time, common aftermarket fixes simply install oversized clearance bearings, which instantly bleeds off vital oil pressure. Choate uses exclusive, proprietary alignment bearings that maintain perfect cam alignment while keeping your oil pressure rock-solid, delivering an average of 5 lbs more oil pressure at startup than competitive builds.

Three Tiers of Power: Find Your Perfect 6.7L Build

We know every truck owner uses their vehicle differently. Whether you need a simple, reliable replacement to get back to work or an armor-plated block to handle massive aftermarket boost, we offer three tailored long block configurations:

1. The Model C (The Budget-Conscious Corrective Build)

If you love your truck close to stock power but want peace of mind, the Model C is for you. It's a budget-friendly long block that skips the high-performance additions but includes our core structural fixes: including the welded crank gear, corrected bearing clearances, and upgraded exhaust valves. You get factory performance without the factory risks.

2. The Daily Driver (The 500+ HP Everyday Icon)

Our most popular option. Designed for spirited street driving, consumer towing, and dependable everyday life, this build is rated for over 500 horsepower. Over the Model C, the Daily Driver introduces full-precision balancing of the rotational assembly, torque plate honing for perfect ring seal geometry, heavy-duty head studs to prevent head gasket lift, a new harmonic balancer, and full upper and lower oil pans installed.

3. The Workhorse (The 600+ HP Extreme Hauler)

Built for the working man who demands absolute, unrelenting reliability under severe structural stress, like heavy commercial hauling or constant fifth-wheel towing. The Workhorse features a Stage 2 Camshaft for optimized airflow, chromoly pushrods, and a welded cam gear. Most importantly, it features O-ringed cylinder heads, cutting a mechanical groove into the sealing surface to lock the gasket down tight against massive cylinder pressures.

4. The Cassquatch (The Ultimate Custom Race Build)

For the elite pulling trucks, competitive drag rigs, or absolute maximum-effort diesel builds, we offer the legendary Cassquatch model. This is our top-tier, zero-compromise racing configuration. Because a true high-level competition engine requires highly specific component configurations tailored directly to your build's exact injector sizing, compound turbo configurations, and horsepower thresholds, you won't find the Cassquatch on our standard web menus.

Every single Cassquatch long block is custom-designed and built-to-order through a direct, 1-on-1 machine shop consultation to ensure your blueprint matches your racing platform's performance criteria perfectly. To learn more about our custom race builds, configure your specs, and secure an accurate custom build quote, you will need to contact our facility directly.

Stop Rebuilding. Start Remanufacturing.

Don't roll the dice on a standard replacement engine that keeps the same design flaws waiting to happen again. From our precision torque-plate honing to our weight-matched piston assemblies, Choate builds are engineered to keep your Super Duty on the job site and out of the shop.

Choosing the Right Build Configuration for Your Truck

Navigating an engine replacement can be tough, which is why we offer our platforms in multiple completion levels to perfectly match your garage setup, mechanical comfort, and budget constraints: