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There are tools to test for exhaust contamination of the coolant. Is the coolant level about an inch below the minimum fill line on the degas resevoir when the engine is cold (overnight) on a level surface? Any signs of coolant escaping from the degas cap? Check carefully for visible leaks (hoses, clamps, radiator core and tank crimps, etc). If the coolant tests negative for exhaust, then you might send an oil sample to a lab to see if you have coolant in the oil. Good luck.
P.S. I am not a tech...maybe one will chime in here with some additional advice.
Not everyone agrees, but I think my MPGs went down quite a bit with the latest flash as well. FICM tuning might help - I haven't tried it yet. I'm not sure about your coolant issues (I'm not a tech). I would check for combustion gases in the coolant. Any white spots under the hood (dried coolant) - I never saw fresh coolant, just dried white spots around the degas bottle. There is a common leak in the lower hose near the steering leakage - it rubs. I think I read another thread where it was only leaking after it got up to pressure so the driveway was clean.
How high do you keep the level in the degas bottle?
While waiting for Tech input, why don't you drive it around, park on a downslope, let it cool a bit and then pull the EGR valve. Check for coolant under the EGR valve.
The degas bottle pressure getting to 16 psig is not normal (mine does not get this high).
ok......
First 16psi is failed head bolts. now if the dealer checked it 3500 miles ago and only got 14psi then its a pass on the test. so its kinda hard to blame the dealer for things that may not have been 3500 miles ago. What we can and can not do is determined by Ford not the dealer.
have you tried to just leave the truck short its 1qt of coolant its droping to see if it will just stay at that level.
for what its worth I run mine 1/2 below the min line
Did you smell any of the residue of that damp spot? Just wondering if it smelled more like coolant than anything else. It does not seem that coolant is in your intake. I wouldn't think the glycol component in the coolant mix would be carried away, but i could be wrong, and I think Cheezit would know more about this. Unfortunately that means it is probably not a failed EGR cooler (an easier fix), and your heads and/or headgaskets may be involved (a more expensive repair). That also fits with your pressure readings that you observed and Cheezit's remarks.
Just for clarification, in going back to your original post are you saying that the EGR cooler was replaced and that the oil cooler and screen were replaced also?