New 6.0 required:$17,000.00
I own 2004 6.0 4X4, no mods, changed oil every 3,000 miles, serviced at recommended intervals. My first problem occurred at 55,00 miles when the EGR valve had to be repalced.At 100,994 miles(994 over warranty) I noticed steam from the exhuast and a sudden increase in engine temp. I thought I had blown a head gasket. The dealer diagnosed as a failed EGR cooler. After picking up the truck I noticed a strange vibration at high RPM. After driving the truck approx 500 miles I also lost 3/4 gallons of coolant with no signs of external leakage. There was no sign of coolant in the oil or vice versa. Engine ran fine. Brought truck back to dealer. The vibration was due to the tech shearing off bolts to the fan while he was trying to change the fan clutch( they had determined it wasn't working on the previous trip). He failed to tell anyone this. They could not find a leak, they simply performed a diagnostic and visually inpected the engine. They did not perforn TSB 06-3-8. ( I learned of this TSB from your site, thanks much!) They stated I was overfilling the tank(NOT).Approx 2 months later the check engine light goes on( I,m still having to add coolant, the rate fluctuating depending on truck usage). The code the dealer finds is P0299 which they say indicates the turbo is dirty or rusted and may need replacement, but it is safe to drive. They reset the light and it never comes back on. 4 months after the initial repair I again have steam coming from the exhuast. This time I take the truck to a different dealer. They find not only ANOTHER BAD EGR COOLER but the head gaskets are bad, scored #2 & #7 cylinders, the exhuast manifold badly rusted and the turbo rusted as well. The original dealer, of course, takes no blame for thier failure to do thier job. If they had done the TSB I would most likely be looking at a head job and not a new motor. I'm now waiting to hear from FMC district rep to see if they will help cover some of the cost( I know, good luck). Truck ran great right to the end of the warranty. New engine is warranted for 2 years/unlimited miles.