I need to add a second, follow up, chapter to my article.
The issues with the truck have been fixed by Ford under warranty - seems to be running fine now.
I finished up leaving the vehicle in Denver with the ER folks so they could take it their local dealer who knows about ERs and 6.4PSD. Bill and his team at ER were very helpful.
We also took out an extended warranty - would recommend that for all 6.0 6.4 PSD owners.
With a few more miles on it the vehicles fuel consumption has improved a little bit 11mpg interstate.
Its taken me a while to get used to the way the Ford works - its a higher revving engine than the Duramax (and the gearing is different). 2000 rpm at 60 mpg Ford 1500 RPM at 60 mph Duramax.
You might get a LOL from the next bit of information and poor planning.
After buying the ER in April (when we thought we would be traveling in North America for the next 2 or 3 years), we decided in June that we wanted to under another extended journey - Russia to Europe, back to South America thence Australia.
We reluctantly decided that the ER camper (which my wife and I both love) on a Ford was not the vehicle for such a trip. I agonized for some time about a Dodge/Cummins as a base vehicle after all Cummins are now being put into Russian Kamaz trucks (see
http://www.wikinvest.com/stock/Cummins_(CMI)/Manufacturing_Entities) and farm equipment - so engine service might be ok in that part of the world. But I did not really want to deal with both a DPF and DEF.
I was eventually convinced that a Mercedes vehicle was the "best" base vehicle - see Jim Rogers book "the Adventure Capitalist" for an interesting discussion of why Mercedes is the right vehicle for a world trip (
http://www.4x4abc.com/JimRogers/ and that I wanted one pre 2006. I looked at a 1017 but they seemed too old and few are available in the US. Then I had an opportunity to buy a US registered 2003 Unimog U500 with VarioPilot which will allow me to import it into Australia permanently as a RHD vehicle. I will post more about the build up of the U500 on my website (and a little bit here) as the story continues to unfolds