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The "never when cold" statement sure points to the HPO system, but they can be hard to diagnose without the proper tools. I have not heard of the fuel pump or the fuel pressure regulator having problems hot, but not cold. I guess it could happen, but I have not read anything talking about it. May be time to bite the bullet and see what Ford diagnostics can tell you.
I misread the "never when cold" part when I posted the first time, so I agree about the HPO thing also. All the 03's and 04's had HPOP problems (knock on wood I haven't) so it's possible the pump or system has a leak. 05's-07's the pump itself has shown to be virtually bulletproof so far, but the rest of the system has a few issues.
Bismic I think you are right I shall do so. I guess while I am at it I may as well get that occasionally dripping egr cooler hose attended to and flush the cooling system I found a site that sells "heavy duty EGR Coolers" anybody have thoughts on that.
You'd be better off to do an EGR delete than getting the HD cooler. It has been discussed previously that, although bulletproof, it doesn't transfer much heat because of the heavy tubing used internally. You can do it but with the California tuning it's gonna give you a CEL unless you can get the PCM reflashed to "alabama" tuning or you get a tuner.
This good to know I have heard California has different tuning I wish I knew the differences Thanks
There are those who can reflash the PCM and FICM to take care of the problem with the California tuning. Power Hungry Performance is in Georgia not that far from Atlanta, so might be worth a days drive. Bill knows his tuning on that kind of stuff.