David Harris
Expedition Leader
A major flaw I am aware of is the fragile and insufficient cooling system. It makes these trucks very easy to overheat which leads to many of the headgasket issues
The cooling system on these trucks is way more than sufficient. It's poor maintenance of the cooling system over time that causes the problem. When the cooling system is in good shape, one can idle these trucks at 120 with the A/C on and they will run at normal temperature. I have done that more than once in Las Vegas during the summer. The cooling system on the pre-99 trucks is better than the later by virtue of the brass radiator which is higher capacity as well.