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The only problems I have seen with the 6.4 are:
-Leaking radiators (hopefully fixed with new venturi "t-fitting")
-Chafed or chewed up pressure control valve and volume control valve wiring harnesses
-Cracked fuel injectors
-Sticking fuel injectors
-Exhuast leak at the turbo downpipe gasket
The biggest problem that causes the most damage is the leaking radiator. The low coolant can cause one or both EGR coolers to burn up, dumping coolant in the engine, bending a rod or breaking the crank. Low coolant can also cause extreme cavitation in the front cover wearing a hole in it, dumping coolant in the oil. Also the smallest particle seems to cause a fuel injector to stick which will cause a no start. No more blown head gaskets due to the removal of the rocker box the 6.0 has. The rocker box is a big aluminum washer in between the head bolt. The 6.4 dosen't have this, its iron to iron.
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Ford Diesel Technician located in Northern California. I'm a mod friendly technician, contact me if you need warranty work in the Sacramento area.
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