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I don't think the 6.0 has any more casting sand than any other engine, I've seen pretty much the same stuff in about the same amount in the first coolant filters for the 7.3 PSD and the 5.9 Dodge gasser motors.
What's different about the 6.0 is it's asymmetric liquid-to-liquid oil cooler, with engine coolant on one side and engine oil on the other side. Guess which side has the smaller passages? Yep, you guessed it, the coolant side.
The oil cooler coolant side is in series and comes before the EGR cooler in coolant flow. Therefore, when the oil cooler coolant passages plug up, it reduces and finally stops coolant flow to the EGR cooler. After enough running time and especially when towing or under heavy load, the EGR cooler fails, sending exhaust gases into the coolant system, end result: "puking" out the degas bottle.
These symptoms look just like failed head gaskets, hence early 6.0 failures were oftentimes misdiagnosed as head gasket failures; this is not to say that the 6.0 doesn't have head problems, it does and the number and size and use of head bolts instead of studs is the culprit.
Hope this helps.
Al
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'06 F-350 SRW 6.0 PSD
Last edited by FTG-05; 10-31-2009 at 01:35 PM.
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