Well, It's been 8 years. 8 VERY Long Years.....
I was one of the unfortunate fools to buy the 2005 SuperDuty.
I should have never sold my '96.
Drive my truck as a personal vehicle. In the spring, I pull a 5th wheel up north
and every spring, the engine blows.
In the fall I pull it back, and the engine blows.
makes for a great vacation every year.
At first I just thought it had a few bugs, and I decided to keep the truck.
by the time I realized it was never going to end, i couldn't sell it (not without
someone coming back to kill me), and i couldn't afford a new truck.
I was stuck.

Ford Dealer Service Department Visits & Repairs
Under Warranty
2005: (8561 Miles)
1. Replace both Head Gaskets
2. Replace EGR & EGR Cooler, Re-Flash Computer

2006: (23012 Miles)
3. Replace both Head Gaskets, Intercooler, 4 Injectors
4. Replace both Head Gaskets, 8 Glow Plugs, Glow Plug Controller, Wiring Harness, Re-Flash Computer
5. Replace Fuel Intensifier / Regulator

2007: (52456 Miles)
6. Replace both Head Gaskets, Fuel Filters, Fan Speed Controller
7. Replace both Heads, Head Gaskets, 8 Injectors

2008: (78130 Miles)
8. Replace EGR Cooler, Intercooler, Oil Leak under Turbo, Serpentine Belts (Dual Alternators)

Not Under Warranty
2009: (100842 miles) yes, 842 miles after the warranty expired.....
9. Replace Turbo, Re-Flash Computer
10. Replace 4 Injectors
11. Replace Cam Sensor & Crank Sensor
12. Replace Tie Rods (wow, a non-engine repair)

2010 (123436) miles
13. Replace both Head Gaskets (seems like a problem to me)
14. Replace Fan Control Unit.
15. Replace EGR Valve.

2011 (NO REPAIRS!!!!) feeling lucky, everything is working, life is good....
then.

2012 (153820 Miles)
16. Replace 3 Glow Plugs
17. Replace Fuel Regulator
18. Replace Serpentine Belts, Idler Pulley

2013 (170324 Miles)
18. Replace Turbo Seal, 3 Injectors
19. Bought Head Stud Kit, EGR Delete Kit, Online and gave it to the dealership. Replaced Head Gaskets, Head Bolts Replaced with Studs, EGR & Cooler Removed, Replace with UpTube, 8 Glow Plugs, GlowPlug / Injector wiring harnesses, Cam Sensor, Crank Sensor.
they claim it will NEVER blow the head gaskets again.
2 years unlimited mileage warranty....
I had the dealership run a repair history, and i kept all the paperwork.
the class action lawsuit covered certain parts, between 100K & 135K miles.
looks like i can recover about 800 bucks.
the truck has 283 service days listed. that's 3/4 of a year in the shop.
Anybody interested in a SuperDuty?

 

Sorry to hear of all the problem's. I am thinking you have a dealer service department problem though!
Were you tuned for all this?
I would have gotten rid of it long ago, if I had the HG's replaced that many time's! LOL
Hope it all goes good from here on out.
Did they tell you why they repeatedly replaced all this stuff every year?

 

Seven sets of head gaskets, two EGR coolers and 27 injectors, but never once the oil cooler or the FICM? You need to find a new shop to spend your money in, they're doing a great of spending it for you without apparently ever finding two of the most common root-cause failures.

 

Yeah too bad you did not do EGR Delete or the studs first... did no one mention them to you? Sorry for your troubles. The 6.0L's I have bought with the Delete/Studs have been good trucks.

 

Oh my.....

 

Sucks to hear, but did you not ask around to other 6.0 owners and ask for advice on all the problems? Also isn't it madness to keep doing the same thing(replacing head gaskets) and expecting different results? Head Studs should have been one of the first things to do, but I guess in hindsight it's always like that. Best of luck to whatever route you go.

 

You need to go back to the source of all this. Silica sand based coolant. Are you using it?

 

sounds like your last repairs should have been your first and you also should not be going back to that place for repairs either.

fixing symptoms does not fix the problem.

 

Find a new dealer, holy crap!

 

I'm sorry, but for someone who joined this forum in 2002, it looks like they didn't utilize one of the best resources available. Right here.

 

Do you really need that Diablo Predator? Early on it was a good idea, but tuning technology has come a long way and there are much better people that tune the 6.0 these days, Like Matt of Gearhead.

I bought my '05 Excursion with an '05 engine a month ago and it ran awesome for the week and a half it was bone stock. I then had Powerstroke Enginuities go through the engine and freshen it up. I thought it ran awesome before, it runs WAY better now.

 

I think someone saw you coming and was thinking about all the $
they could take from you and your insurance/warrantee

Come on over here and do some reading in the Tech Folder at the top.
6.0L Power Stroke Diesel - Ford Truck Enthusiasts Forums


I think that Texastech_diesel hit this nail on the head.

Sean

 

X100

Too many crooks out there, apparently you found some.

 

We too bought a brand new 2005 6.0, long story short:

replaced engine with new crated one 5,855 miles after 43 days owned.
215 days in shop first 14 months
48 injectors
4 turbos
2 steering sectors
3 dash units
3 high press. fuel pumps
ect. ect. ect.

dealer has receipts for $66,000 +/- parts under warranty, sticker $53,000 +/- we pulled large stock trailer to ranch 7-8 times a week, 450 mile R.T.

had an appointment in Omaha for a mediation trial under Lemon law, we were "required" to have the F-350 4 door Lariat long box 4x4 at meeting, well it was in shop again, so I hauled it with my 2001 P.S. to meeting.
Ford rep was on phone. Mediator said truck was in impeccable condition inside and out with 71,000 + miles and Ford claimed we had "excessive use" so didn't deserve any compensation !

BTW, we had it at 6 different dealers, including Woodhouse !

Still own it today, currently has 132,000 miles and doesn't leave the shed much.

Love our 3 2012 F-350's with 6.7

 

I'll buy either "pos" trucks from y'all

Just saying. I'd put money that the true cause was never fixed. Kinda like a dog chasing his own tail


Sorry you guys had so many issues though.