This is a 6.0 Diesel? This could be a sign of a serious condition. When these engines overheat, the head bolts stretch and cause the head gaskets to leak. The compression from the combustion chambers pressurize the cooling system, and cause the leak from the coolant bottle. You have 2 symptoms of this common problem of the 6.0 diesel. Take it to your local Ford dealer for the appropriate repairs. If you have under 100K miles and have everything on the engine is STOCK, it will be covered under warranty.

If you are satisfied with my answer, please accept.

Thanks,

Loy

Anything is possible, but I know that the concern you have is a common failure. I hope that it's as simple as a plugged radiator. I found this TSB

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TSB 08-11-3	COOLANT LOSS - 6.0L
Publication Date: May 16, 2008

This article supersedes TSB 08-3-7 to update the Service Procedure.

ISSUE:

Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2008 E-Series vehicles, all equipped with a 6.0L engine, may exhibit:

• Coolant venting from the degas bottle cap
• No-crank/no-start
• Coolant leak
• White smoke from tail pipe
• Low coolant
• Lacks power overheat
• No cabin heat

The conditions typically occur when operating the vehicle under a load such as trailer towing, uphill driving, or both.

ACTION:

Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

Prior to making any repairs, verify the coolant level is not overfull. The new coolant fill level is at the "MIN" line of the degas bottle cold. Overfilled coolant levels will cause coolant to vent from the degas bottle cap.

Complete All Steps In Order As Outlined

1. Testing the degas bottle and pressure cap for proper operation of the pressure cap and its seal to the degas bottle:
   1. Do not remove the pressure cap.
   2. Install a pressure tester in-line with the degas bottle hose using Rotunda 014-R1068 adapter. (Figure 1)
      
      
      Figure 1 - Article 08-11-3
      
      
   3. Pressurize the cooling system by using slow and steady pump action on the tester pump handle. Quick or rapid pumps on the tester handle may cause false readings. Pressurize the system until the gauge pressure levels off, between 12-18 psi (83-124 kPa).
   4. The degas cap should release between 12-18 psi (83-124 kPa) allowing the pressure to level off.
      1. If the degas cap releases with less than 12 psi (83 kPa), replace the cap.
      2. If degas cap was replaced, apply pressure and wait 30 seconds for pressure to stabilize.
      3. If the gauge pressure drops:
         1. Apply soapy water around the cap to find any leaks.
         2. Check the degas bottle fill neck lip for nicks or cracks. Small nicks can be removed by light sanding with fine emery cloth.
         3. Re-pressure test, if leaks are still present replace the pressure cap if not already replaced in a previous step.
         4. Re-pressurize the system and test again, if leaks are still present replace the degas bottle, Refer to WSM, Section 303-03.
   5. After verifying that the degas bottle, pressure cap and cooling system are in good condition, proceed to Step 2.
2. EGR Cooler Leak Test On Vehicle:
   1. Install RADKITPLUSA 078-00592 on the degas tank.
   2. Regulate shop air to 100 psi (690 kPa) and apply vacuum to cooling system until gauge stops decreasing or 20 inches of vacuum is reached. (Degas bottle coolant level must be set to "MIN" line with a cold engine to allow sufficient space for vacuum.)
   3. Hold vacuum and allow vacuum to stabilize.
      1. If vacuum holds steady over 15 minutes proceed to Step 5.
      2. If vacuum does not hold steady over 15 minutes proceed to Step 3.
3. EGR Cooler Leak Test Off Vehicle:
   1. Remove the EGR cooler from the engine following Workshop Manual (WSM), Section 303-08.
   2. Install cooler block-off tools (Figure2) and pressurize the EGR cooler to 30 psi (207 kPa). Fasten the inlet and outlet port block-off plates using standard bolts, nuts and washers. (Figure 2)
      
      
      Figure 2 - Article 08-11-3
      
      
   3. Submerge the EGR cooler in water and inspect for bubbles.
      1. If bubbles identify a leak, replace the EGR cooler and proceed to Step 4.
      2. If bubbles do not identify a leak proceed to Step 4 and re-install the original EGR cooler.
4. Testing Oil Cooler:
   1. Gain access to the top of the oil cooler following WSM, Section 303-01C; only necessary steps since the EGR cooler is out of the vehicle. The test can be performed without removing the entire oil cooler from the engine.
   2. Apply the RADKITPLUSA as shown. (Figure 3) Regulate shop air to 100 psi (690 kPa) and apply vacuum to rear coolant port removing all residual coolant. The oil cooler must be free of coolant. Residual coolant will cause a false gauge reading.
   3. Stop the flow of shop air once the residual coolant has been removed.
   4. With the RADKITPLUSA still attached regulate shop air to 100 psi (690 kPa) and apply vacuum to rear coolant port. If RADKITPLUSA gauge needle moves from the rest / full stop position (indicating vacuum), replace the oil cooler. (Figure 3)
      
      
      Figure 3 - Article 08-11-3
      
      

      CAUTION:

      COOLANT ENTERING ANY COMBUSTION CHAMBER MAY CAUSE A HYDRO LOCK CONDITION. EVACUATE INTAKE PASSAGES AND COMBUSTION CHAMBERS OF ALL LIQUIDS USING A SUCTION DEVICE. REMOVE GLOW PLUGS (REFER TO WSM, SECTION 303-07B) TO ASSIST IN VENTING LIQUID FROM COMBUSTION CHAMBERS, BEFORE ENGINE IS STARTED.

       

   5. Re-assemble engine, fill the cooling system, perform Step 5a - 5e and proceed to Step 6b.
5. Road Test Setup And Observations:
   1. Install the IDS PVT, or Rotunda Pressure Adapter Kit 014-00761, or equivalent. (Figure 4)
      
      
      Figure 4 - Article 08-11-3
      
      
   2. Carefully release the cooling system pressure, leaving the tester in place.
   3. Seal pressure bleed.
   4. Drive the vehicle at wide open throttle (WOT) / high load / maximum boost.
   5. Observe whether the cooling system pressure exceeds the holding pressure of 12-18 psi (83-124 kPa) noted in Step 1.
   6. Check for coolant venting through the degas bottle cap by listening for a hissing noise.
   7. Observe ECT and EOT PID's on IDS Datalogger. EOT maximum temperature differential might occur at throttle tip-out.
6. Road Test Evaluation:

   Follow IDS PVT Datalogger instructions on screen.

   1. If EOT is within 25 degrees of the ECT and the cooling system pressure is less than the holding pressure as noted in Step 1 proceed to Step 7.
   2. If EOT exceeds ECT by 25 degrees at any time during the test, replace the oil cooler and leak check the EGR cooler off vehicle using procedure in Step 3. Repeat Step 5 following oil cooler replacement.

      NOTE:

      DO NOT REPLACE HEAD GASKETS IF COOLING SYSTEM PRESSURE EXCEEDS DEGAS CAP HOLDING PRESSURE WHEN EOT EXCEEDS ECT BY 25 DEGREES.

       

   3. If the cooling system pressure is greater than the holding pressure noted in Step 1, and/or the degas bottle cap continuously vents when loading the engine and the EOT is within 25 degrees of the ECT, perform PC/ED Cooling System Diagnostics for the Vistronic Fan Clutch. If Vistronic Fan Clutch passes or has been replaced continue to Step 8. If Vistronic Fan Clutch fails replace the Vistronic Fan Clutch and repeat Step 5.
   4. If the EGR cooler passes the off-engine leak check, if no other leaks are found and if cooling system pressure is greater than the holding pressure noted in Step 1, and/or the degas bottle cap continuously vents with loaded engine, perform PC/ED Cooling System Diagnostics for the Vistronic Fan Clutch. If Vistronic Fan Clutch passes or has been replaced continue to Step 8. If Vistronic Fan Clutch fails replace the Vistronic Fan Clutch and repeat Step 5.
   5. If the EOT is within 25 degrees of the ECT and the cooling system pressure is less than the holding pressure noted is step 1 proceed to Step 9.

      CAUTION:

      CAREFULLY RELEASE THE COOLING SYSTEM PRESSURE WHILE REMOVING DEGAS CAP.

       

7. On Vehicle EGR Cooler Leak Test With Engine Warm:
   1. Install RADKITPLUSA on the degas tank.
   2. Regulate shop air to 100 psi (690 kPa) and apply vacuum to cooling system until gauge stops decreasing or 20 inches of vacuum is reached. (Degas bottle coolant level must be set to "MIN" line with a cold engine to allow sufficient space for vacuum.)
   3. Hold vacuum and allow vacuum to stabilize.
   4. If vacuum holds steady over 15 minutes proceed to Step 6c-e.
   5. If vacuum does not hold steady over 15 minutes proceed to Step 3 and 4 to test the EGR Cooler off the vehicle and testing oil cooler on vehicle.
8. Head Gasket Replacement:
   1. Refer to WSM, Section 303-01C for head removal/installation and head flatness specification and replace the head gaskets.
   2. Check the surface of the heads for flatness and/or imperfections. Refer to WSM, Section 303-00 for the REVISED cylinder head flatness measuring procedures.
   3. Use the following revised head bolt torque sequence and specifications. (Figure 5) Refer to TSB 07-10-4 for cylinder head identification.
      
      
      Figure 5 - Article 08-11-3
      
      

      NOTE:

      THE CYLINDER HEAD MUST BE CLEANED PRIOR TO CHECKING FOR FLATNESS OR YOU WILL GET IMPROPER READINGS.

      CAUTION:

      IF THE INJECTORS ARE LEFT IN THE CYLINDER HEADS DURING THE REMOVAL OR INSTALLATION PROCESS INJECTOR DAMAGE CAN OCCUR.

       

   4. Cylinder Head Handling Tips.
      • Avoid banging, dragging or scratching the cylinder head at all times. When removing the cylinder head, lift the cylinder head straight up off of the dowels so as not to nick the cylinder head.
      • Once the cylinder head is removed, place the cylinder head on a bench with the gasket side up. If the gasket surface must be turned down, use a piece of clean cardboard on the bench surface to protect the cylinder head from damage. Do not allow the cylinder head to slide on the gasket surface, even on cardboard.
   5. Cleaning Cylinder Head Deck Surface.

      The only tools approved by Ford Motor Company for cleaning the cylinder head and deck surface are plastic (Figure 6) and wood scrapers, combined with the use of Motorcraft®Metal Surface Prep. Ensure that the mating cylinder block deck surface is completely free of solid contamination, corrosion, and fluids.

      NOTE:

      STAINING OF THE METAL SURFACE IS CONSIDERED NORMAL AND DOES NOT AFFECT SEALING ABILITY.

      CAUTION:

      DO NOT CLEAN DECK SURFACES UNDER ANY CIRCUMSTANCE WITH STEEL RAZOR BLADES, ROTARY ABRASIVE DEVICES, OR ABRASIVES INCLUDING: ROLOCTM AND 3M BRANDED SCOTCHBRITETM PRODUCTS OR EQUIVALENTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVES SUCH AS SANDPAPER OR EMERY CLOTH, ANY CARBON STEEL BLADE. THESE PRODUCTS WILL CUT AND DAMAGE DECK SURFACES RESULTING IN LEAKS. ABRASIVE PARTICLES MAY ALSO ENTER THE ENGINE CAVITIES CAUSING INTERNAL ENGINE DAMAGE. USE OF THESE TOOLS CAN ALSO GREATLY AFFECT THE FLATNESS OF THE SURFACE.

      
      
      
      Figure 6 - Article 08-11-3

9. Vehicle Assembly:
   1. If the oil cooler, EGR cooler, or head gaskets have been replaced, flush the cooling and heater system together using Motorcraft® Premium Cooling System Flush.
   2. Use RADKITPLUSA 078-00592 to fill cooling system. Refer to WSM 303-03.
   3. Change engine oil and oil filter.

      NOTE:

      ON 2004 E-SERIES 6.0L BUILT BEFORE 05/29/2004: IF THE OIL COOLER IS REPLACED, ALSO REPLACE THE HEATER CORE INLET HOSE; THE REVISED HOSE CONTAINS AN INTERNAL FLOW RESTRICTOR (FIGURE 7). REFER TO TSB 05-2-5 FOR ADDITIONAL INFORMATION.

      
      
      
      Figure 7 - Article 08-11-3

   4. Remove the EBP sensor wire connector and inspect weather seal. If the seal is missing, replace the connector and EBP sensor.
   5. Check for diagnostic trouble codes (DTCs). Perform the following inspection and tests.
      1. For 2004 (built after 9/29/03) - 2006 F-Super Duty and 2004 (built after 9/29/03) - 2005 Excursion: reprogram the powertrain control module (PCM) to the latest calibration using IDS release B39.12 and higher. This calibration contains a revised cooling fan strategy to help reduce the occurrence of coolant venting. Calibration files may also be obtained at www.motorcraft.com.
   6. Perform Turbo Boost Test.
      1. If test FAILS refer to PC/ED Turbo Diagnostic Pinpoint Test KA for further details.
      2. If test passes, repairs complete.

         NOTE:

         OVER-BOOST CONDITIONS (HIGHER THAN SPECIFIED MGP) WILL RESULT IN EXCESSIVE CYLINDER PRESSURES, AND MAY BE CAUSED BY ONE OF THE FOLLOWING: IRREGULAR RESPONSE IN VARIABLE GEOMETRY TURBO, BIASED EXHAUST PRESSURE SENSOR, AND/OR IRREGULAR EXHAUST GAS RECIRCULATION.

          

Figure 8 - Article 08-11-3

OTHER APPLICABLE ARTICLES:

07-10-4, 05-2-5

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

DEALER CODING

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.

Copyright © 2008 Ford Motor Company

I cannot stress how important it is to have your engine stock. Anything that was added on or modified from the day you bought the truck will cause the warranty repair to turn into a customer pay job! Put it back to stock if anything has been modified.

Please accept my answer if you are satisfied.

Thanks,

Loy