About a month ago we started to notice this high-pitched whine sound when accelerating. It eventually got to where the sound would be constant, so we took it in to the dealer who said it was a sheared bolt on the exhaust manifold. 140k miles, warranty is kaput, $75 in parts for new bolts and gasket(s), had to apparently yank the cab off to fix it, $1600. Got them talked down to $1k though.
A couple of weeks go by, sound came back. It was faint at first, but then it became loud and constant. Took it back to the dealership, their diesel "specialist" took one look under the truck and said "your radiator is gone". Not literally gone, but pretty much fried. Opened the hood and popped the cap off of the coolant reservoir and steam came shooting out. Guy said he has to replace them almost daily on the 6.4. Another $600 there. While working on it he noticed the thermostat was shot, thus causing the failure to the radiator. Another $100 to replace that. He probably knew this was the problem the first time and just got the rest of his money that he "discounted" us.
Just out of curiosity, he pulled the service record off the VIN for all the work that had been done to the truck, including the previous owner of it. The radiator had been replaced at 40k and had gone 100k before needing a new one. The guy said that was a good sign, that the radiators usually go for 50-60k before just giving out. This is happening because these radiators move twice as much water per minute compared to a normal diesel radiator, 70gpm being the norm, 140gpm on the ones for these 6.4's. They just get that hot!
So we think all is good, had the truck for a few days now, and the sound is back. Now what the hell else could it be? A torn or loose hose? The guy we deal with is this dealer's only diesel specialist, he's a nice guy, and they are local. But obviously he either doesn't care, or is just not doing all that is necessary to find the problem. Hell, we pulled the truck off the lot and the AC wouldn't cool. Swung back around and had them recharge it.
Nice guy or not, he's only as honest as the dealership he works for. And we're finding out the dealer is not a good one. We've never bought from them, but they are local.
They guy pulled us aside and said to start looking for a new truck. He said don't touch ANY 6.4 that was built in '07-'08. The majority of problems were fixed on the Gen 3 builds starting in '09. But he said if it were him, he would get an '07 6.0. But like my dad said, going from the '08 to the '07 would be like wiping with sandpaper when you've got Charmin right in front of you. He told us that the pushrods were strengthened in the '07s, or something like that. Can't afford brand spankin' new, but a few slightly used, super low mile '09s are starting to pop up. Heck, even brand new ones that dealers are clearing out for '10 have up to $10k off the sticker. But still, cheapest we've found is still $20k more than we spent on the one we've got now. But...about $3k has been spent on this truck since buying it in Feb. So it's almost justified to have a $200 a month more payment for a truck that's not constantly in the shop.
Oh, and get this, the tech also told us this. The way the lines are routed and hooked up to the computer and guages..you will never know the truck is overheating. We didn't know ours was because the temp guage stayed in the normal position the entire time. He said Ford knows these problems, and basically since they didn't build the engine, they don't give a crap what happens to it. Hence why they are building the Scorpion 6.7. But you guys already knew that.
It still sucks though for us guys that own these trucks and are stuck with them. At least you low mileage owners still have the factory warranty to cover your butt. Be thankful for that. It's a great truck, when it's working. It would be a kick in the balls to have to go back to a Cummins. Good engine (pre BlueTec), but a crappy truck wrapped around it.