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You need an oasis on the truck you want and read lots about what to watch out for. Only the 6.0 in the 03 and 04 years had problems, I think if you stick to 05 or later you should be ok. Its possible to get a problem child but check the oasis and you can avoid that. I have an 05 and have been very happy with it. Looks like you are do for a new truck so you can do some new mods anyways. The 6.0 makes probably about the same power you are making with all that work on the 7.3. So, when you do mods you have to be more careful. For chips and other HP mods I think you need to do head studs first. I have not done these mods yet but would like to chip mine but I still have some engine warrenty left.
Got any statistics to verify that? I know 12 people personally with 05 and 06 6.0's who are part of the RV camping crew I travel with . I have seen 4 sets of blown headgaskets in 05's and 06's and these trucks had 20-40k fewer miles than my 03 and mine has original gaskets. They use the same TTY bolts in the later models. You hear on this site the regurgitated statement that 05's and newer are more reliable but I'm not so sure. The 05 HPOP is a serious issue that will leave you on the side of the highway for sure. I've seen that three times. The earlier model issues were mainly caused by programming problems that have been corrected. I think the reliability of an 03/04 that has been flashed properly is just as good as any 05/06. I'm sure an 07 is probably better. Don't forget the earlier models used LSD fuel which was harder on the EGR valve. Now we have a fuel that combusts with less particulate matter. What I observe happening to the trucks that I'm familiar with does not always correlate with the "03/04 trucks are bad" opinion. They WERE bad, but I don't agree with that opinion lately.
If you drive it frequently on longer trips with load you probably won't have problems with it. The turbo problems occur when you they sit for weeks on end and when they do a lot of short trips around town and don't get warmed up properly. EGR problems also occur with the short town trips.
Just a comment on the "lot rot" turbo problems (letting them sit for long periods of time). The machining change to fix that problem aparently was very successful -- check your build date on the '06 you are considering, if it's later than mid Jan '06, you've got the upgraded (fixed) turbo.
Since it sounds like you'll be on the road a lot, full timing it, I probably wouldn't worry even if was an earlier unit....
I looked long and hard for a diesel 6.0 in the 03 and 04 years and looked at numerous Oasis reports. Every one showed numerous problems, and not just the EGR. I ended up waiting for a 05 for that reason. I am sure the headgaskets and HPOP can be an issue in any 6.0 like you say but I figure as long as I watch my gauges, dont use a chip foolishly if I ever get one, I seem to have a good one. I am about half way through my engine warrenty and well past truck warrenty so we will see. I guess I would rather have a 6.0 than a newer with DPF ect. I would like to do the EGR program off and a SCT with custom tunes and especially a tow with turbo braking one day.
I am in Northern BC, Canada. THere are more HD trucks than anything on the road around here and they get worked. I think especially for pastormike he should look at 05 or better 6.0. That being said an older 03 04 with a good oasis would be good, but I am just warning him OASIS OASIS OASIS. KNow what you are getting into.
Oh yeah, I had a leaf front 5.4 SD 350 and the front end sucked turning tight. So, that is another reason for the 05 or better coil front end. Its better IMO 2.
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