fla-gypsy wrote:
I suspect the overwhelming majority of the much maligned 6.0L PSD motors are reliable and required no more repairs than other makes. The internet always accentuates the bad and creates many false narratives. No doubt there were issues and considering the number of these that were sold equals many bad motors. Percentage of failures we will never actually know and even if we did it would be impossible to sort out the self induced issues from the bad production ones. Reputation is always a hard thing to overcome and this is a classic case of it. Many people here still believe that Ford diesel motors are not as good and are prone to failure even though reality says otherwise. Much like the mythical quality gap between domestic and foreign produced vehicles that ended 20+ years ago many still spout the mantra regardless of the truth.
Ford released a statement saying that the 6.0 was the most expensive mistake they ever made. It cost more in warranty repairs per vehicle than any other engine they've ever made. That's why they didn't offer them for very long. They've re-engineered a lot of the more trouble-prone parts, like the variable vane geometry turbo. They had so many issues with them that Ford actually purchased some of the early trucks back from the owners.
It was their first attempt at complying with the new EPA regulations for diesels and they tried a lot of innovative design changes. Most of the owners didn't know about the strict servicing requirements until problems started.