The replacement FICM is still subject to issues if you let your electrical system get low on voltage (batteries or alternator). If it ever craters on you again, it is easy to fix (FICMrepair.com will upgrade some weak components and re-flow the circuitboard solder at a reasonable price).
The OEM EGR cooler is a weak point. A new one should be fine for many years if you properly maintain your coolant system, but the BulletProofDiesel one is MUCH better. Some people delete the EGR system as the solution.
The failed EGR cooler and oil cooler comes from the coolant plugging up in the oil cooler passageways. This starves the EGR cooler for flow and it fails. If you are using Ford Gold coolant, flush it EVERY 50K miles and use distilled water. Do not mix coolants. Keep an eye on the coolant level in the degas bottle and do not let it get too low. The proper level in the degas bottle is at the "Min Mark". Some people have switched to ELC EC-1 coolant. That is probably a good move. Coolant filters are also a good idea,
All year models are marginal on fuel pressure in MANY of these engines. Install an add-on fuel pressure gauge in addition to the Edge Insight (or equivalent - scangaugeII, etc). If your fuel pressure is below 50 psig at WOT (below 45 psig is VERY bad for injectors), then you need the updated fuel pressure regulator spring.
The 05's and up have a weak connection on the discharge of the high pressure oil pump. This connection, the STC fitting, needs to be replaced with the upgraded part. Also, the original dummy plugs and standppes are prone to leaking high pressure oil and should be replaced with the updated parts. You can do a search on the topic and find lots of info. You don;t have to do this upgrade right-away, but it is adviseable.
Go to the dealership and get an OASIS report - ask for a full report. It will list all of the warranty repairs. Post up the info you get and folks might see some other things to pass on to you.
Last edited by bismic; 11-20-2011 at 04:31 PM.