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The second picture looks kind of like an injector tip to me. I have seen one embedding in a piston before. But if that were the case, the injector in that cylinder should be missing it's tip..
The wire, I have no ideas on.
What is Ford saying you did to cause this? If the truck is truly stock, I would make them put their reasons for denial in writing and then go up the food chain.
BTW, to my knowledge, there are no DTCs for a bad EGR cooler. There are DTCs for a malfunctioning EGR valve but not the cooler..
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 2003 Toreador Red/ Arizona Beige CC, DRW, Lariat, FX4, 6.0 PSD, Torqshift, born early Feb. 03; AIC; Silverline turbo-back dual exhaust; 155cc injectors from Full Force Diesel (Casserly); SCT with tuning by Tony Wildman (Total Diesel Performance) & Innovative Diesel; ARP studs; Dfuser regulated return; AFE PG7; Fumoto valve; B&W hitch, Di-Pricol gauges; DIESELSITE Coolant filter; Timbrens; Rancho RSXs; Michelin XPS Traction's; a whole bunch of "bling"; Connex 4300hp; Pioneer DEH6100BT; JL Audio 275w amp driving a 12" sub; JL Audio 50wx4 amp driving the Alpine door and rear seat speakers. 380.3hp/786.7ft-lbs (on my tow tune!)
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#43
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