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I think a lot of the EGR and cooler issues are caused by not working the motor hard enough.
This seems to be a very popular opinion. Also read in another thread Ford redesigned this system in '15 so will try to be watching for those years to see if they also end up posting with problems or if the redesign works better. Bought mine used, when I called the shop listed on Carfax that did most of the service on mine he said it was an oil field fleet vehicle, lots of highway miles and probably left idling on the job site. I'm assuming high idle times are very bad for these egr systems, more so than just regular driving, grocery getting. NO idea if he towed or not but there's no ball in the bed and the paint on the hitch looked brand new so I'm guessing not. The truck is perfect inside and out, looks brand new. It does look like something was bolted into the bed though, I'm guessing a transfer fuel tank.
Forgot to mention part of my big bill was for a new oil vacuum lift pump gasket, noticed some oil dripping down the front of motor during my hunt for escaping coolant. Another classic fail point for these motors it seems. Hoping I'm squared away for a while.
what I saw in the 2008-2010 models with the first generation of the DPF with heavy use of the EGR was pretty much the same thing. Not as bad as a 6.0 but still the trend was those who worked the motor had fewer problems then those that did not..
If that is the case it should be interesting then when Ford releases the 3.0 powerstroke later this year. Those will be in half ton trucks, some of which get worked very hard, most of which are grocery getters, trips to Lows, etc. How will those engines, egr systems, hold up with the light duty? I haven't paid any attention to the Ram ecodiesel, not sure how the emissions have fared in that motor but I think there's been some problems with the motor in general. Maybe the smaller displacement is much easier to deal with emissions wise? Chevy will be launching their 3.0l next year I think, good luck to the early adopters is what I'm thinking.