Have you had the newest CAC installed per TSB 11-2-2? It just came out Feb 2011 and has a brand new part number.
I got the latest CAC installed in my truck from ford about 3 weeks ago or so and my problem is gone (FINALLY!).
This must be what your referring too.
2008-2010 F-Super Duty
This article supersedes TSB 8-25-1 to remove the production build date, update the vehiclemodel years and Part List. ISSUE:
Some 2008-2010 F-Super Duty 250-550 vehicles equipped with a 6.4L diesel engine may exhibit significant amounts of white smoke from the exhaust pipe while driving in high humidity or rainy conditions at temperatures above 4 °C (40 °F). This smoke only appears during a moderate to full throttle tip-in that is performed after a period of steady state driving.
Follow the Service Procedure steps to correct the condition.
This procedure only applies if the vehicle meets the following criteria:
Concern is described as significant amounts of white smoke from the exhaust pipe.
White smoke only occurs in high humidity or rainy conditions above 4 °C (40 °F).
White smoke only appears during a moderate to heavy tip-in that is performed after a period of steady state driving (approximately 20 minutes)
No diagnostic trouble codes (DTCs) are present.
Concern is not a result of regeneration, a cleaning exhaust filter event.
If all of the criteria above is true, then replace the charge air cooler (CAC) assembly with a new revised part per Workshop Manual, Section 303-12.
Some white smoke may still be present under severe conditions even after the new level CAC has been installed. This is considered a design characteristic of the charge air system and no repair attempts should be made. This concern does not affect the life of the engine or exhaust components.
PART NUMBER PART NAME
7C3Z-6K775-C Charge Air Cooler Assembly
Eligible Under Provisions Of NewVehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
110202A 2008-2010 F-Super Duty 6.4L: Replace The Charge Air Cooler, Includes Time To Check For DTCs (Do Not Use With 6775A, 12650D) 0.7 Hr.
BASIC PART NO. CONDITION CODE
I've had the original, then the TSB unit but not a revised one. So are you saying you had the 1st revised CAC per the original TSB and now your on your second one for the latest TSB in February?