CEL came on a while back and I pulled the code which showed a fault in the NOx sensor bank 1, sensor 1 specifically.

I ordered and installed the new sensor and cleared the code and the CEL went away for a couple of days before returning.

I also was notified of a recall requiring the PCM to be reprogrammed because they were having problems with codes being thrown when there was no issue. I scheduled and had this work done by the local dealership and the code went away for about a week before coming back.

Not sure what to do at this point with a brand new sensor installed and associated recall service completed. Any ideas?

For reference 2022 f250 6.7 with 59k miles.

Isn't that covered under the 5/100 powertrain?

Probably but ford will reimburse me for the part and I don't want to schedule that service at the local dealership (bluebonnet) bc their service dept is always backed up forever for a part I swapped out in 15min in my driveway.

Do you still have the original sensor? If so, replace Bank 1 sensor 2 with the original sensor. Those codes are usually thrown because of an "efficiency" standard isn't met, meaning the NOX reading between sensor 1 and sensor 2 isn't big enough. In that scenario, either sensor can be bad/ drifting and you'll get the same error code. So it could be the downstream sensor is the bad one, not the upstream.

Along those same lines, in terms of NOX removal efficiency, you could have a problem with the DEF. Bad/weak DEF fluid, a bad DEF injector, or weak DEF pump.

What is the exact code?