2011 Ford F-350 Super Duty

Reliability tier: verified - see /disclosure/

Engine: 6.7L (Power Stroke, 6.7L)

gen1 - 400hp/800lb-ft (mid-2011 ECU reflash from launch spec 390hp/735lb-ft; free dealer upgrade, no hardware change); Garrett GT32 single-sequential turbo on ceramic bearings, Bosch CP4.2 pump, TorqShift 6-speed

Applicable failure modes (11)

• Dual-circuit cooling system leaks (radiator / crossover tube / degas bottle / water pump)
• CP4.2 high-pressure fuel pump contamination cascade
• DEF / SCR / NOx sensor faults
• DPF clogging / regeneration problems
• EGR cooler thermal-fatigue coolant leak
• EGR valve soot clogging / sticking
• Low-pressure fuel supply weakness (lift pump, filters, water-in-fuel)
• Glow plug wear and cold-start faults, plus an isolated 2011-2013 tip-separation defect
• Piezo injector wear and fuel dilution of engine oil
• Intercooler condensation ingestion + cold-side charge-pipe fatigue
• VGT turbocharger failure - generation dependent (ceramic-bearing GT32 vs journal-bearing GT37+)

Applicable parts (32)

• Banks Power Boost Tube System, hot and cold side (2011-2016 6.7L Power Stroke)
• 6.7L Power Stroke EGR Cooler Upgrade with H-Core Technology, 2011-2024 (Bullet Proof Diesel)
• 6.7L Power Stroke Coolant Crossover Tube (Ford BC3Z-8C471-A, 2011-2016)
• ford-powerstroke-6_7: coolant-hose (honest catalog gap)
• 6.7L Power Stroke CP4.2 High-Pressure Fuel Injection Pump
• DEF (Diesel Exhaust Fluid) Injector
• DEF (Diesel Exhaust Fluid) Injector (current service PN AL3Z-5J281-B)
• 6.7L Power Stroke DEF Reservoir Assembly (Ford BC3Z-5J225-K, 2011-2012)
• 6.7L Power Stroke EGR Cooler (Heat Exchanger), gen1/gen2
• EGR Cooler Seal Kit
• EGR Cooler Seal Kit (current service PN BC3Z-9P455-B)
• Exhaust Gas Temperature (EGT) Sensor, single
• 6.7L Power Stroke Fuel Contamination Repair Kit, 2011-2022 (XDP / Alliant Power)
• 6.7L Power Stroke Fuel Filter Element (Ford BC3Z-9N184-B, 2011-2016)
• 6.7L Power Stroke Billet Fuel Filter Housing / Leak Prevention Kit (S&S Diesel Motorsport)
• 6.7L Power Stroke Glow Plug
• Glow Plug Control Module, 2011 only
• 6.7L Power Stroke Fuel Injection Kit, Chassis Cab/gen1-shared (Narrow Frame), Cylinders 1/2/7/8
• 6.7L Power Stroke Fuel Injection Kit, Chassis Cab/gen1-shared (Narrow Frame), Cylinders 3/4/5/6
• 6.7L Power Stroke In-Tank Low-Pressure Lift Pump, gen1 (2011-2014)
• 6.7L Power Stroke CP4-to-DCR Pump Conversion (S&S Diesel Motorsport)
• 6.7L Power Stroke CP4 Disaster Prevention Bypass Kit, Gen2.1 (S&S Diesel Motorsport)
• 6.7L Power Stroke LPK/DPK Replacement Filter Kit (S&S Diesel Motorsport)
• 6.7L Power Stroke Thermostat, Driver Side
• 6.7L Power Stroke Turbocharger Pedestal Gasket
• 6.7L Power Stroke Turbocharger Assembly (gen1, GT32 ceramic-bearing)
• 6.7L Power Stroke Turbocharger Assembly (gen1, GT32 ceramic-bearing) (current service PN BC3Z-6K682-C)
• 6.7L Power Stroke Auxiliary Water Pump, Dual Alternators
• 6.7L Power Stroke Auxiliary Water Pump, Single Alternator
• 6.7L Power Stroke Primary (Engine) Water Pump, gen1/gen2
• 6.7L Power Stroke Main Radiator, XDP X-TRA Cool XD291 (2011-2016)
• 6.7L Power Stroke Secondary Radiator, XDP X-TRA Cool XD299 (2011-2016)

Platform recipes (5)

• Aftertreatment repair for the 2011-2022 6.7 (modes fm-ps67-def-system / fm-ps67-dpf-clog): sensors lie first - verify the DPS and EGT sensors before any assembly spend
• Full repair path after a confirmed CP4.2 high-pressure pump contamination event (fm-ps67-cp4-fuel-pump): metal debris in the fuel filter means the pump, injectors, rails, and lines are all contaminated, not just the pump
• Preventive measures against the CP4.2 contamination cascade (fm-ps67-cp4-fuel-pump) and the separately-documented plastic fuel-filter-housing cracking issue (fm-ps67-fuel-delivery) - cheap insurance against the platform's single costliest failure mode, applicable across all three generations since the CP4.2 pump has been used throughout (an aftermarket parts maker's 6.7L Power Stroke guide, a parts retailer's 6.7L Power Stroke guide)
• EGR repair by generation (modes fm-ps67-egr-valve / fm-ps67-egr-cooler): the 6.7's EGR hardware is generation- AND frame-split
• Turbocharger repair for fm-ps67-vgt-turbo - and the platform's clearest illustration of why generation matters: gen1 (2011-2014, Garrett GT32 ceramic-bearing) and gen3 (2020-22, per Ford's own catalog note) use ENTIRELY DIFFERENT turbocharger assembly part numbers (BC3Z-6K682-A/C vs LC3Z-6K682-A) - ordering the wrong one is not a simple supersession mistake, it is the wrong physical part

Recalls that include this truck (1)

• 13V-535 (October 30, 2013) - ENGINE: Ford Motor Company (Ford) is recalling certain model year 2011-2012 F-350/450/550 Ambulance Package vehicles manufactured February 22, 2010, through October 19, 2012 and equipped with a 6.7L diesel engine. Due to an...

Matched by the model and model year NHTSA lists for each recall - a recall often covers only part of a year's production, so read its text for the build dates and versions it names. Whether a recall is still open on your VIN is not known here; check nhtsa.gov/recalls. All recalls, investigations and bulletins for this engine: /recalls/ford-powerstroke-6_7/

Reference for this truck