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My '04 started BILLOWING white anti-freeze smelling smoke. Managed to get home and call the dealer. They have heard of a "few, but not many". Thanks God for the warranty!
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"A few but not many"? wow great dealer... Do a search and you will find hundreds of posts. For a while back in 04 into 05 it was a common post.
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Some owners are buying a set of ARP head studs (stronger then original bolts) and having the dealer reassemble with the studs. They allow more clamping force and will reduce the chances of future problems. They (ford/international) also released a better head gasket in response to the problem. Make sure your dealer uses them... I would expect the new gaskets to be the only one available but by asking you are letting them know, you know what is going on...
Do a search and be armed. As long as the truck is stock you should not have any problems with ford covering the repair but be sure to ask the dealer how they plan to change the gaskets. Some mechanics just grin and bearing it and pulling the heads as the truck sits. Some are actually lifting the cab off the frame and doing the job that way. Believe it or not this actually appears to be the best way to do it but if the mechanic is not careful they can scratch something, crush something or pinch something causing more problems.
Let us know how you make out.
Good luck,
mark
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