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Discussion Starter #1
These forums are great things. Problem is you find them when it is too late. For the common guy driving a pickup truck pulling a 5th wheel we (I) like to leave the service up to the mechanic. In my case I have trusted Ford Service. I and my wife looked forward to this nice long trip not even thinking there would be a problem since I had it into Ford Service before we left on our trip. A computer component that monitors fuel distribution was replace for a $1000. I have a chip that also does this, which I questioned with the mechanic, and said it had no effect. We live in Michigan. Arriving in Calgary, Alberta I stopped at a Ford Service to see why I was losing coolant. They diagnosed faulty EGR cooler. $3800 later the job was done. When we got on the road again I was losing more coolant than before. The Ford mechanic wrote up that the head gasket(s) were leaking. Was the replacement of the EGR cooler and Oil cooler really needed? So the story goes you learn the hard way.
 

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Sorry to hear about the issues you have had. Unfortunately, many of these symptoms are similar to the average technician who doesn't deal with the 6.0L diesels on a frequent basis. It sounds like the case that you have here. In most cases, a leaking EGR cooler allows coolant to enter the cylinder and causes the head gaskets to blow. It is likely that is the cause in your case as well. Best of luck in getting your truck fixed up.

PS. My truck is my tow vehicle as well and I have installed a bunch of parts in order to ensure I don't have those same failures again. (I've been through 4 EGR coolers).
 

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Discussion Starter #3
To Evil Eye. Thanks for the reassuring (not) news. The answer to the EGR is to delete it or more correctly plug it up to avoid further problems. What I still do not understand is that the head gasket test should be made in conjunction with the EGR test. To do this would identify the real or source of the problem rather than a band-aid.
 

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The unfortunate part of egr cooler and head gasket failures is that once the egr cooler is blown there is no way to tell if they head gaskets are blown until the egr cooler is repaired. I just put one back together that had a popped egr cooler and then popped headgaskets on top of it. I figure the headgaskets were blown first and the low coolant resulted in the damaged egr cooler. Customer had been adding coolant for a few months now. Claimed he never saw any smoke.
 
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