For anyone who's had trouble with their 6.0 Powerstroke... I understand! Mine's out of warranty now, and I took it to the dealer to have an overheating and coolant puking problem diagnosed. They quoted 2600 bucks to replace a bad EGR cooler (3rd one to fail on this truck). That was really just the start, because normally the EGR cooler takes out the oil cooler and sometimes the turbo, so things could have gotten ugly fast. Said "F this" and decided to fix Ford's problem, hopefully once and for all. Bought a kit from Liberator Performance that includes a new turbo up-pipe that has no EGR passage, a coolant bypass tube to replace the EGR cooler, and a block plate for the intake. Found a great deal on a new oil cooler on Ebay for less than half what Ford would charge. Bought new water pump, hoses and belt for maintenance purposes while I was in there. Also added a new larger intercooler, coolant filter setup, higher efficiency radiator, and upgraded fuel line fittings and pressure regulator to keep the injectors happy. Here are a few pics of the mess.
What your 6.0 looks like underneath all that crap with the intake removed. The oil cooler and filter base are still installed:
Closeup of the modified up-pipe that feeds the turbo. Important mod - heat shield on the y-pipe has been trimmed to allow access to the bolts from the top. They're a real bitch to get to from the bottom unless you have a lift:
Intake manifold with POS EGR cooler still installed:
Bottom of intake with bypass tube and block plate installed:
New toy, nice part from Spearco (Turbonetics):
Ever wonder what the inside of a VGT turbo looks like? Dirty:
Lot of work, but learned a LOT. Bought a real Ford shop manual before I started - 200 bucks but worth it. Probably would not have had the courage to start this job without it. Saved lots of cursing and broken sh_t! Truck seems to be running again, drove it to work today. Real test will be next time the boat is hooked up and we're headed up a big hill...