Blog

If you are in the market for a new diesel engine - whether it's a Powerstroke, Duramax, or Cummins - you probably have a dozen tabs open on your browser and a lot of questions. We get it. Buying an engine is a massive investment, and whether you are recovering from an engine failure or just looking for an upgrade, you need straight answers.

At Choate Performance, we receive countless emails from first-time diesel owners and veterans alike regarding turbo sizes, injectors, and build specifications. Read on (or check out the video above) to learn the answers to the most common questions we get from customers looking for a 6.4 Powerstroke build.

Daily Driver vs. Workhorse: Which Should You Choose?

The most common question we get about the 6.4L Powerstroke is which engine tier to buy.

First off, keep in mind that we offer our engines in four tiers:

When it comes to the 6.4L Powerstroke, while a daily driver can usually handle the job, we often recommend the workhorse package if it fits your budget. Here is why:

• Bang for Your Buck: The workhorse is a package deal that includes upgrades like a stage 2 camshaft, chromoly pushrods, and coated pistons. If you bought these parts individually, it would cost significantly more.
• Performance and Longevity: This setup is designed for heavier loads and higher temperatures. The stage 2 cam helps reduce exhaust gas temperatures (EGTs), and the chromoly pushrods combat deflection.
• Economy: You often see increased fuel mileage and better overall performance.

Even if you aren't towing heavy loads 24/7, stepping up to the workhorse offers gains all the way around.

What Makes A Choate 6.4 Powerstroke Engine Reliable?

What makes our daily driver more reliable than a stock OEM replacement? The answer is simple: Machining, machining, machining.

We stand by the idea that stock is not an option. We don’t just throw parts at a block; we correct the geometry.

• Deck Surfacing: Many manufacturers (including some big names) do not deck the block surface. We do. When you mate two perfectly flat surfaces (the head and the block), they seal significantly better. This is crucial for keeping head gaskets intact.
• Main Line and Concentricity: We ensure the crankshaft main bore housing and the crankshaft mains are true and concentric. Without this, you get uneven bearing wear and side loading.
• Thrust Bearing Alignment: We ensure the thrust bearing is perpendicular to the face of the crankshaft to spread the load evenly.

Whether you buy a daily driver or a high-performance race series engine, the machining standards and documentation are exactly the same.

Must-Have Upgrades For Longevity

Every platform has its weak points. For the Duramax, keying the crankshaft is key (ba-dum-tss). It's especially important for these high performance engines (although we do it for stock builds as well) as they are more likely to shear the factory dowel pin, which can lead to catastrophic failure. However, for the 6.4 Powerstroke, the absolute must-have addition is valve covers with an integrated oiling system.

The OEM 6.4 suffers from rocker arm wear that affects preload, leading to lifter and camshaft failure. We've seen studies that show it can take up to 3-5 minutes for oil to reach and adequately lubricate the rocker arms on start up. Our integrated oiling system solves this problem by delivering immediate and consistent oil flow to the valve train.

Sending In Your Core vs. Buying a Built Engine

Is it better to have your specific core remanufactured? In our experience, it makes no difference regarding longevity - provided the core is qualified.

We are extremely picky about cores. For example, we avoid the notorious ' Code 53 blocks' on Cummins engines due to cracking issues. Similarly, there are specific 6.4 blocks that are prone to cracking, and we filter those out during our inspection process. If you buy an engine from us, you are getting a block that has passed rigorous testing, regardless of whether it was originally yours or one from our inventory.

Tuning And Installation Tips

Once you have your new engine, the two things that can destroy it fastest are:

• Bad Tuning
• Installation Errors

First, let's address tuning. We steer clear of tuning here at Choate for obvious reasons - we've seen many tunes over the years and can quickly identify a tune that's going to cost you engine life.

Typically, injection timing after 28 degrees is considered no man's land. It generates extreme cylinder pressure and heat without increasing power, often causing piston melting and cracked blocks. The danger of bad tunes is that we cannot offer warranty coverage for melted pistons or bent rods caused by overly aggressive tuning.

On to installation. When it comes to installation, specialization is our superpower. We've worked with a specific set of engines for decades, so we've seen their evolution and know the faults that can occur across various model years. If, for any reason, you don't receive exactly the parts you need to install your engine correctly - or if you (or your mechanic) have any doubts or questions about the installation process, please reach out to us - don't wing it.

We've heard of cases where an installer convinced someone to install a 6.0L flex plate on their 6.4L, which is not a good idea since there's a 220-gram weight difference (give or take) between them. The 6.4 pistons are heavier, requiring a specific counterweight on the flex plate. Using the wrong one will destroy your bearings.

Additionally, we've seen issues with aftermarket water pump impellers being pressed on too far. If the impeller bottoms out against the front cover, it can strip the shaft or create shavings, smoking a cylinder within a few thousand miles. A simple check with modeling clay during install can save your entire engine - we can walk you through it.

The bottom line is, please use us - we're happy to be a resource to pass along tips and tricks that will keep your new engine in tip-top shape during install and for years to come.

6.4L Powerstroke Diesels From Choate Engineering

We want you to have a successful build - if you are unsure about a part, a tune, or an install step, just pick up the phone and ask us.

Ready to start your build? Give us a call at 901-553-9847 or visit ChoatePerformance.com to send us an email. Browse our Powerstroke offerings above and let our experience work for you!