Just had the oil cooler and high pressure oil pump replaced on my (176K miles) 4X4 '04 Excursion and when my wrench, Bob McDonald, [ http://www.amazon.com/Rebuild-Stroke-Diesel-Engines-Workbench/dp/1934709611
] tested it we heard a hissing from the front and no power from the turbo. The intercooler sprung a leak, Found that the rubber gasket had popped out of front and rear of the right lower plastic tank connection to the aluminum core.
I either hadn't noticed or heard of this problem but it was another chunk o' change from my wallet.
So far done: EGR bypass, ball joints, idler pulley, turbo rebuilt, tie rod, chrome running boards (rusted out on right rear), heater core "Y" hose and roof rack cross bar. Haven't added a programmed chip so I don't have any issues with the head bolts or gaskets, yet.
I will probably be putting it on the block to upgrade my ride. Check out:
2004 Ford Excursion