I own an Ford '06 6.0 diesel 4x4 Sportsmobile and would NEVER buy another 6.0 Ford diesel.
Mine has had two turbos replaced, the first at 6,000 miles. I have had to stop at Ford dealers on a couple different long vacation trips to have them diagnose the check engine light, which loves to come on when you are far from home. To say the least, having the check engine light come on during a vacation does NOT help my mood to be relaxed... The first time the light came on the dealer said they thought it had something to do with the fuel tank, but didn't know what it was. This was actually the second dealer that I stopped at this day, as the first one asked my if I had an appointment and when I said no, I was on vacation and was traveling through town, he simply said they might get to it in a few days... I have had the check engine light come on in central Oregon and it was half a days drive to get to Burns, the nearest dealer. I wasn't planning on going to Burns either... The said it was again a turbo fault, but just cleared it and sent me on my way. They also said 3/4 of their business was trucks, and most of them were diesels. They said they had changed lots of turbos.
I have had several Ford service reps tell me that if I drove the van like a service vehicle, all day long every day, it would be better for the turbo. Seems that using it like an RV, which it is, by driving it long distances and then parking it for weeks, hurts the turbo. It gets rusty inside. Well, I can't imagine having a service rep on any other vehicle suggest that I change my life style to suit the vehicle. Like anyone would drive their van an hour a day because it was good for it???...
Both times the turbo "failed" on my van it was over boosting just slightly and it seemed to be running fine. But if I kept driving it and it actually failed, would Ford then cover it? I doubt it. Seems like Ford's fix for any trouble with a turbo is to just swap it out. That's OK, as long as they are paying for it, but it still pisses me off that I have had this much trouble and stress from a truck that has only 40,000 miles on it. Yeah, this is my $100,000 "get away" vehicle that I have serious doubts about taking anywhere far from a dealer. Go figure...
The drive train warranty is for 100,000 miles. Ford used to have an extended warranty you could buy that would cover another 100,000 miles, but they canceled that offer for any vans converted to 4x4, regardless of who did the conversion. Sportsmobile is a factory authorized Ford RV upfitter, but Ford will not sell an extended warranty to cover a 4x4 SMB.
I was driving across town tonight and the light came on again, so tomorrow I'll call the local Ford dealer and drop it off again. Just thought I'd vent a little tonight...
Brian Rutherford