Turbocharger failures have been common on 2011 and 2012 model year 6.7L Power Stroke equipped pickups. The weak link in the Honeywell DualBoost turbo during early production years seems to be the ceramic ball bearings. Reliability concerns with the turbocharger were eradicated with the introduction of steel ball bearings. A turbo failure on these model years is hard to miss, as an obnoxiously loud screeching sound is exhibited in addition to smoke being emitted out of the tailpipe due to burning engine oil. As the turbocharger design is relatively advanced, it's also quite expensive to replace.
Early build 2011 model year pickups equipped with the 6.7L Power Stroke diesel often developed radiator leaks of varying severity. It has been reasoned that radiators in pickups built prior to September 2010 were defective from the factory. Persistent problems in later model years has not been identified with any considerable frequency, but that is not to say that radiators from later model years have not developed leaks over time.
NOx Sensor Failures
NOx sensor failures were extremely common on 2011 model year engines. Under certain conditions, engine power is reduced as a result of a faulty NOx sensor. Frequent sensor failures on a large scale prompted Ford to initiate Custom Satisfaction Program 12B33, in which technicians checked and replaced faulty sensors in addition to uploading an upgraded emission control strategy for the SCR system. The Customer Satisfaction Program expired April 30th, 2013.
EGT Sensor on "Ambulance Package" Chassis Cab Trucks
At least one faulty EGT sensor was identified on 2001 and 2012 model year F-350/F-450/F-550 trucks equipped with the "Ambulance Package". The emissions aftertreatment system on the 6.7L Power Stroke diesel features several EGT sensors. When one of these sensors fails, a vehicle may shut down while driving and/or fail to restart. Considerable controversy resulted as emergency vehicles were left stranded, prompting Ford recall 13S10 to replace the faulty sensor(s). Similar instances have been reported in pickup models, although these incidents appear much more isolated and have not contributed to widespread concern.
Dropping Glow Plugs, Catastrophic Engine Failure
There have been multiple reports that the glow plug tip on early production 6.7L Power Strokes may break off into the engine, causing a catastrophic failure. These incidents were not widespread and there have not been enough cases to prompt a recall or any considerable concern in later production engines. The problem seems to be isolated to certain chassis cab models. Had Ford detected a problem with the factory glow plugs, a recall or service bulletin would have been likely in order to reduce the onset of expensive warranty claims.