Soot Problems

• Older Power Stroke diesels developed a reputation for creating huge amounts of soot, which would deposit itself inside the exhaust gas recirculation (EGR) cooler and variable-vane turbocharger. EGR clogging can lead to turbo overboosting, and soot in the turbo can lead to malfunction of the turbo's internals.
  
  

Mechanical Failure

• Older Power Stroke diesels had Torque-to-Yield (TTY) bolts, which permanently stretch when torqued to keep the cylinder head on the engine. These TTY bolts are prone to failure under the higher boost levels seen in even lightly modified engines.
  
  

Emissions Recall

• On September 29, 2003, Ford issued a recall (number 06E17) for any truck built before that date, intended to address faulty computer programming that caused malfunction of the truck's Exhaust Backpressure Sensor (EBP). a faulty EBP can cause hard starting, a rough idle, excessive smoke and loss of power.