4 common IPR Sensor Failure Symptoms on 6.4 Powerstroke

Some car troubles tend to pop out of nowhere. You can be sailing across the street one day. The next day, you may not be able to start the engine. What do you do to not get caught off guard by these issues?  You keep a close eye on the symptoms. 

For example, catching the symptoms of 6.4 Powerstroke IPR Sensor Failure can save you a lot of trouble. These symptoms are grinding noises, engine surging, random stalls, and a dead engine. The causes are lack of lubrication, dirt, faulty components, and wear and tear.

Chances are you might have some questions. For example, where do these grinding noises come from? In this guide, I’ll answer that question and any others you may have about IPR sensor issues.

6.4 Powerstroke IPR Sensor Failure Symptoms chart

6.4 Powerstroke IPR Sensor Failure Symptoms & Causes

The 6.4 Powerstroke IPR sensor can fail for a myriad of reasons. This table attempts to link the most common symptoms with the likely cause of the issue. 

Again, if any of these topics seem a little intimidating or hard to understand, there is no need to panic. I’ll cover every symptom and its likely cause in depth further down the article. 

IPR Sensor Failure SymptomsCommon Causes
Grinding NoisesLack Of Lubrication
Engine SurgingDirt And Debris
Random StallsDamaged Components
Dead EngineWear and Tear

While there are many symptoms to look out for when it comes to an IPR valve being damaged, these 4 tend to pop up the most. 

#1- Grinding Noises

If you hear grinding noises from the engine, there is definitely something wrong with your vehicle. You should instantly pop open the hood to see if something is stuck in it. If not, the IPR may be damaged.

It’s one of the easiest symptoms to spot. This noise won’t be faint; you’ll certainly notice it.

#2- Engine Surging 

Have you ever faced a sudden shift in the speed of your car? This is called engine surging. Your engine suddenly gives more power than it needs to. This will cause 

the acceleration to be uncontrollable. 

This is a really dangerous issue as it can cause an accident. If you ever see this symptom, rush to your nearest mechanic. 

#3- Random Stalls 

Equally as dangerous as the previous symptom, random stalls mean the engine shuts down completely out of the blue. As you can imagine, this would be a total nightmare on the highway. 

#4- Dead Engine

Last but not the least, this is the worst-case scenario. If your car never starts, it means that your engine isn’t starting. Sometimes, you’ll even hear a crank but the car just won’t budge. 

Why Did Your 6.4 Powerstroke IPR Sensor Fail?

Now that you know the symptoms, it’s time to take a deep dive into the 4 most likely causes of these issues. 

1. Lack Of Lubrication

The grinding sounds may be that of the metal parts of your car rubbing against each other. The IPR valve may get damaged from this friction. Ensure that you use good engine oil to keep everything well-lubricated. 

2. Dirt And Debris

Some people take hours cleaning the exterior of their cars but never even bother opening the hood. You need to ensure that you clean the internal components of your car every once in a while. Otherwise, the accumulated dust can cause real problems.

3. Damaged Components

The IPR valve is an advanced component that is made up of several parts. If any of these parts are damaged, the IPR valve itself won’t work. The components that may be damaged are 

  • External O Rings
  • Actuator piston
  • Pilot valve

4. Wear and Tear

An IPR valve is generally a sturdy component that lasts as long as the engine itself. That said, every component of your car will eventually get worn out. The case is no different for the IPR valve. 

Other Car Issues That May Cause The Same Symptoms

Just like the symptoms and causes may overlap, these issues can overlap with a damaged IPR valve as well and lead to the same symptoms. 

  • Damaged ICP Sensor

The ICP sensor is right next to the IPR valve and it forms the part of the system that monitors oil pressure. If this component is busted, the valve won’t be able to regulate the level appropriately. 

  • Dead Battery

Engine issues have so many possible causes that it would take you days to list them down. The most common one however is a dead battery. If the component that powers it isn’t working, the engine won’t work either. 

  • Ignition Switch Issues

Ignition switches turn your car on and off. Hence, issues in this part of your car can definitely cause stalls or shut down the engine completely. If you do hear a crank, however, this is probably not the causing factor. 

  • Transmission Problems 

Transmission issues also cause the performance of your car to be greatly affected. Make sure you can differentiate the engine surges from sudden gear shifts. The latter is almost definitely caused by transmission problems. 

How To Fix The 6.4 Powerstroke IPR Sensor? 4 easy steps

Fixing an IPR sensor is a highly complicated process. For starters, you can’t really fix this component. It needs to be replaced. I adamantly suggest that you go to a mechanic for this process as you may damage your car further if you try DIY fixes.

This step-by-step guide should tell you how to get your IPR valve replaced at the auto shop properly. 

  • Step 1:  Proper Diagnosis

Be sure there is actually something wrong with your car. Sometimes, symptoms just pop up and disappear randomly. These don’t warrant immediate checkups.

  • Step 2: Find A Good Mechanic 

If you already know a reliable auto shop, you’re one step ahead. If you don’t, you’ll need to do a bit of research. Reach out to fellow car enthusiasts for recommendations. If that isn’t possible, the internet should be your last resort. 

  • Step 3: Inspect The Process

As the process should take no longer than an hour, you can oversee the entire procedure. This isn’t always possible though as mechanics usually have a lot of cars to work on before getting to your problem. 

  • Step 4: Test The Vehicle Before Leaving The Shop

This last step is something that a lot of people forget to do but it is vital. Ensure that everything is in order before taking your car out of the shop. This makes sure that you don’t hit the road with a faulty vehicle or get scammed.  

Frequently Asked Questions (FAQs)

1. What is the IPR Valve?

The IPR valve or the IPR sensor is a component that controls the level of oil pressure in the high-pressure oil pump. IPR stands for an injection pressure regulator. This component is very important for your engine. 

2. Is It Safe To Drive With A Broken IPR Valve?

The answer is a strict no. Automotive defects were the leading cause reason for 44,000 of the 2.2 million accidents according to a survey by the National Highway Traffic Safety Administration. Hence, it is highly irresponsible to drive a damaged car. 

3. How Expensive Is An IPR Valve? 

An IPR valve should cost no more than $200. This price will depend on a lot of factors such as the model of your engine and where you are buying the valve from. Keep in mind that this isn’t the only cost you need to bear: mechanic fees tend to be high. 

4. Is The 6.4 Powerstroke A Good Engine? 

The 6.4 Powerstroke is the go-to choice if you are looking for a heavy-duty engine. There’s a reason why it is the engine of choice for the Ford Super Duty series.

How to diagnose your truck’s IPR | Symptoms of bad IPR >> Check out the video below:

Final Words 

I’ve covered all the most common 6.4 Powerstroke IPR sensor failure symptoms. However, they aren’t the only telltale signs that your engine is having issues. There are plenty of other rare problems that may indicate this error. 

How do you stop this issue, then? The only answer is proper car maintenance and regular trips to the mechanic. Ensure that you take your car to the auto shop every once in a while.

Who Worked on This post?



Anderson is an experienced auto mechanic with over 10 years in the industry. He is skilled in diagnosing and repairing a wide range of vehicles, from sedans to trucks and SUV

Syed Ahmed


Syed Ahmed has been working as an auto mechanic editor for the past five years. He has a background in mechanical engineering and a love for all things automotive

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