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I feel your pain, but it sounds more like "dealer service nightmare" than 6.4 nightmare, and unfortunately it's pretty much par for the course. In 30 yrs of dealing off and on with dealership service depts I've only known one that didn't have their heads so far up their ***** they could see their tonsils. Naturally they got closed up when the big 3 were purging.
It seems the bigger/busier they are the worse it gets. I had one completely rebuild an engine, transmission, transfer case, replace a slew of engine computers and other do-dads and never ever change the problem one bit.
Too bad for Ford that one was on their dime. Lemon law was mentioned, as was "lawyer", along with "shotgun maintenance" and "Ford rep". "Here's a brand new Bronco" was the reply.
The 2nd one was the best most reliable thing I'd ever had, till I bought my next new Ford.
At least your dealer seems to be stepping up, and while maybe better late than never, I think on the right track with head gaskets.
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