My 04 F350 6.0 overheated slightly. I stopped to let it cool down and removed the reservoir cap and found oil in the coolant. I was in a bind so I tried to put water in it but it would'nt take any. I took off and it got real hot real quick. I sent it to the dealer and they are replacing the oil cooler and the egr cooler. The mechanic says he will run a test after he puts it back together to make sure there is no head damage from the heat. Cost for repairs 2700.00 because I am at 105,000 miles just out of warranty.
Now I have been a ford man all my life, I love my truck, but I am worried that it is about to start costing me a bundle of money. I don't want to buy a new one because I use it for work and that brings scratches grease on the leather etc. This truck is me, it is personalized by me for me. I don't want to get rid of it. The mechanic told me he would'nt own a 6.0 that was out of warranty because of all the problems. Has anyone else experienced these problems?

 

Frankashaw- If you checkout older threads you will see all of the problems you are having have happened to others.

 

another reason a coolant filter is a good idea.

 

And a better reason to turn off the EGR and install an EGR up-pipe delete.

 

Frank,
Sorry to hear about your trouble having been there myself less than a year ago. I was 200 miles from home at a dealer a didn't know and w/out my laptop w/ my contact numbers for people in the know, like Matt at LIPD. I spent close to $4K to cure my overheating for a new EGR, EGR valve, intake manifold and turbo that had all been "poached" by the ruptured EGR. That EGR is $900 and the EGR delete is a little over $200. I paid the $900 and now it has disappeared and the delete is in its place, no chance of the catastrophic failure again.

There are a couple of design issues that haunt the 6.0 but they all can be remedied by some reengineering. The EGR prob listed above, warping of heads (stretching of head-bolts) causing compression leaks, and injector issues probably top the short list. EGR remedy per above. Head warpage remedy by LIPD's coolant flow mod and some headstuds, and injector issues corrected by a return regulated fuel system that keeps air out of the injectors curing the factory dead-end issues. From here the "optional" short list could include coolant filtration, oil bypass filtration, Fluidampr and some others that don't necessarily fix design flaws but should add much protection/life to your 6.0 PSD.

You will spend some dough on these mods but it will be money well spent and should add many, many trouble free miles to a great engine and your baby. Comparing these expenses to the cost of a new Dodge or Chevy/GMC which have their own "issues" I think you'll come out OK. Good luck man and give Matt or Jeremy a call at LIPD to talk about these design issues for more insight.

 

Thank God, my truck is done today. It passed the test whatever they call it for head gasket leakage and all is well. Can't wait to pick it up in the morning. I'm gonna be like a kid on christmas eve tonight. I'll be doing the coolant filter and egr delete this week. I'll be getting back with LIPD on the tuner in a couple of weeks. (need some time to financially recover) Many thanks to you guys for your input. I'll be around.