Powerstroke Head Gasket Replacement Cost Detail Breakdown for You!

How much is the cost to replace the 6.4L Powerstroke head gasket? Generally, Ford Powerstroke head gasket replacement cost ranges from $2500 to $4500. Sometimes it becomes higher.

There are some facts which can reduce the cost to the minimum. You can avoid the high expense if you know why the 6.4 Powerstroke head gasket replacement cost increases.

Here on this page, you will know the cost of replacing the head gasket, the labor cost and labor hours, why the cost increase, and how to decrease it. Let’s dig deep to learn every point.

How Is the Powerstroke Head Gasket Replacement Cost?

The Powerstroke engine is an innovative engine type in Ford history. The 6.4L Powerstroke ran only from the 2008 to 2010 edition. The engine assembly is pretty complicated and huge to have the power of running larger versions of Ford trucks.

Replacing the head gasket on the 6.4 Powerstroke engine is a costly project. Only some repairs may solve the problem if only some parts are damaged. Repairs are not so expensive as replacements.

To replace the entire head gasket set, you may have to pay $3000 to $9000. Yes, the variation range is so long. Sometimes you may need to replace the head parts, and then the cost reduces and stays within your affordability range. Sometimes, it becomes enormous and may be over $9000.

Head Gasket Replacement Cost Breakdown

Generally, the head gasket set price is approximately $698. The cost of a head gasket set installer, including studs, cylinder head, and others, ranges from $1564 to $2614. So, the price for one set becomes $2262 to $3312. Now you have to add the labor cost to the head gasket set and installer. And this increases the cost to a high level.

Labor Cost

Technician charges $30 to $100 per hour. Depending on the work limit or damage extension, labor time ranges from 3 to 8 hours. When the damage is only a few parts of the head gasket assembly, the cost reduces in both matters. You only have to purchase the damaged parts for the entire head gasket, and the labor time will also decrease. So, the total cost will be low.

State Fees/ Other Charges

The head gasket replacement cost does vary by region too much. You may get a little difference in the head gasket replacement cost of the 6.4 Powerstroke engine in different areas. For example, California’s head gasket replacement cost will vary from $3694 to $4500. In Massachusetts, the price ranges from $3200 to $4500.

As mentioned above, the cost sometimes becomes enormous. One of the victims from Forestry Forum had a head gasket in his car and had to spend $9500. His 2008 Ford 6.4 head gasket replacement cost was so high because he had to replace and purchase a new oil cooler, new cylinder heads,

So additional parts, for example, ARP head bolts, new rocker arms, pivots, water pumps, new belt idler assemblies, thermostats, and other parts, can increase the total cost. 

But why the cost varies so much? The reasons behind the high head gasket replacement cost are- the vehicle’s age, the damage’s severity, other further problems related to the damage, and labor cost. The higher the damage issues, the higher the labor time and cost.

Some simple leaks can increase if you run your truck longer in this situation. Then it can blow the head gasket. When you find a few symptoms of head gasket issues with the 6.4 Powerstroke, you must stop and make the necessary repair. It can minimize the cost and eliminate the chance of real head gasket damage.

Sometimes, you can reduce the cost by using a temporary K-seal repair. But it can work only to a limited extent. If leaks are from coolant to cylinder or cylinder to coolant or coolant to oil, K-seal work for longer. But after running the vehicle for a few weeks, you may need to replace the head gasket.

Why is it Worth Replacing the 6.4 Head Gasket?

Many people want to know if the truck can run with the blown head gasket in the engine. The answer is Yes. Your vehicle can run for a few hours or up to 60 km. But this is not recommended.

If a head gasket in the 6.4 Powerstroke fails, gases start to leak to the coolant or coolant leaks to the cylinders. When you keep running your Ford, the engine gets hot, and the leak damages the cylinder heads. If the head gasket assembly gets completely damaged, you will have a problem with the engine starting, or the truck may stop suddenly.

The head gasket replacement cost can be high, but it is necessary. Without it, your truck is entirely out of order. The engine will idle or stall or knock down. The blown head gasket can ruin the entire machine.

So, it is worth spending on your head gasket replacement.

A Helpful Tutorial You May Need!

Frequently Asked Questions (FAQs)

How do I know if my 6.4 Powerstroke has a blown head gasket?

When your Ford has blown a head gasket in its 6.4 Powerstroke engine, the truck will start to show some symptoms. The Powerstroke engine starts to increase the temperature while running the car. Again, the engine gauge will deliver the highest temperature within a few minutes. Also, your truck will get a cloud of exhaust fumes and white fumes.

How many labor hours does it take to replace a head gasket?

Generally, a technician needs three to eight hours to replace the entire head gasket. When most parts of the head gasket are damaged, you must replace most parts with new ones. Then the labor hours increase. If you have most parts or all the parts of the head gasket damaged, you cannot replace it in less than six hours.

What is the cost to replace the head gasket on F250?

The replacement of the head gasket of the 2008 F250 takes high costs ranging from $2481 to $4500. When you replace more parts in the head gasket assembly, you have to give more labor time, and the cost will also increase. Generally, the labor cost ranges from $1222 to $1642.

Does a blown head gasket indicate getting a new engine?

If you run the truck with a blown head gasket caused by a leak, it will severely damage the engine. Then only a head gasket replacement cannot solve the issue altogether. After running the truck for a few hours with the replaced head gasket, you will face problems with your engine again. Only head gasket replacement is adequate if the damage is through the engine block and cylinder head damage.


The head gasket is a significant part of the Powerstroke engine. Though it seems like only a connection seal between the cylinder head and engine block, it can be worse when the head gasket is blown. Depending on the head gasket damage extension, you may need to replace the entire engine, which is much more expensive.

Though the 6.4 Powerstroke head gasket replacement cost is high, it is worth replacing before the severity of the damage increase. From the above discussion, you understood that you could reduce the damage extension and repair or replacement cost by making immediate repairs. However, running a vehicle with a blown head gasket can damage the engine. So, replace the head gasket of your truck if it is necessary.

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