6.0 => Evil No Bad, Hot, Don't Touch, Run Away
Background
I Love Super Duties. I have owned one 7.3, three 6.0, and have a 6.7 on order. They are awesome for towing, long trips, daily drivers, and work well off-road for a big heavy truck.
I am good friends with two Diesel Master Mechanics.
As you read this, remember I just put my order in for a new 2013 6.7.
I would never recommend a 6.0 to anyone. I would hesitate to give one away to anyone who did not have $10K to throw at the motor between parts and labor.
What are the issues?
The motor is its stock configuration will most likely prematurely fail, even when normal recommended maintenance is followed.
It is more than just the EGR. The high pressure oil system can leave you sitting at the side of the road.... and don't forget the turbo failures... ICP sensor failure … then there are the oil leaks …
The failure of the system can be quiet dramatic with the coolant boiling off over time, taking silicates out of suspension, plugging up coolers, generating more heat, coolers failing, dumping coolant into the intake, stretching head-bolts, leaking head gaskets, killing injectors.
If you really want to learn about this, talk to a diesel mechanic for a school district that has the 6.0's in the van style configuration. They can tell you how much “fun” they are having pulling motors trying to get them fixed. Hint: Van compartment, poor cooling, high temps.
So you want to “fix it”
The EGR is a big problem area, as this is where the coolant starts boiling off. Planning to do an EGR delete? An EGR delete is illegal for on-road use. In the PRK (Peoples Republic of California) Diesels are smog checked including a visual inspection. For those of you, who will accept the liability of violating smog laws; consider the creative use of a welder on your original equipment.
I don't know if you have had the opportunity to see the high pressure oil seal failure…. But the good news is that we may have found out where the engineers from Morton-Thiokol went after the Challenger disaster. The tubes with the O-Rings are way in the back of the motor, make sure you pull them and replace with the upgraded parts. This can be done when replacing the oil cooler and egr cooler. When you do that the turbo is out, you can make sure that that is not all carbon crusted because the previous owner never would punch it.
Oh yeah then there is the great joy to be had in getting rid of the gold coolant to be replaced with a non-silicate based coolant. The wash rinse repeat is very time consuming.
Options
Keep changing the coolant and have the Ford dealer use the new ultra-cool tool to remove silicates from the coolant, and throw on a coolant filter.
You may be able to buy an extended warranty from Ford depending on the age of the truck so when it fails you don't have a big bill. You are still stuck on the side of the road, but you don't have a big bill.
Buy a 7.3 and have the tranny upgraded.
Buy a 6.0 pull the engine and swap in a Dodge motor.
If you absolutely need to buy a 6.0
See title at the top.