egr will show all the same signs as a blown HG.

That is true the egr will show similiar signs to a blown head gasket. I would pull the cab put headstuds in and while your at it put an egr delete kit in it and run it. Just my opinion we have 4 f 550's at work. if you can swing it i would upgrade the turbo while the cabs off just easier to do. as our bone stock trucks blow headgaskets and seem to go through egr's.

Blowing Coolant
 

Well I am sorry to here that you are having a problem with your coolant and overflow. I had t same problem since day one I bought my truck back in 04. I had my truck in the shop 4 different time. I took it to the Ford dealership in Carthage, Ny; Watertown, Ny; Munce, Ind; and then finally to Moser Ford in Portland Indiana. The mechanic there has 18yrs experience with stock and high performance diesels. I had left my truck with him for a few days and to come find out, it had a head problem. Listen, this is a factory problem. On the 6.0, the head bolts come loose after a few thousand miles. Under normal driving you wouldnt notice any blowout of collant. Never once did I see any coolant in my oil. Only under boost would I notice coolant blowing out of the coolant box. Ford will swear up and down to you that you have no head problem. However, if the would tear your heads off, you would see the blow-by (something similar to blow head gaskets). It isnt a EGR problem. I wouldnt take "NO" for an answer. I can give you the contact info for the mechanic if needed. Also if you call EDGE and BANKS, they will tell you the same thing about the head bolts. If you have notice, your truck doesnt get as good of fuel mileage as it did once you first bought it. During on of your recalls or oil changes, Ford burns a new factory tune into your computers rom. The did this to back off the horse power and eliminate the pressure on the heads to keep the bolts from coming lose.

Ford has never done an oil change on my truck or been able to flash my computer. I have contacted Banks about it they didn't care to hear about my problem (must depend on who you talk to). Anyhow my waranty is over, so i got them changed at NADP in edmonton alberta, they also did an EGR delete and the truck seems to run alot smoother now( might just be me). thanks anyways.:c:

I have the same problem. I am loosing coolant but i dont see it leaking. The res. is low about every 2 or 3 days. when i am driving on the highway and i do about 75-80 for a period of time it sound like a loud fan running and (this amy sound wierd) it smells like water.????? planning on taking it in to dealer.I have 94,000 miles and I want to get it in before 100,000 warranty is up.

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Ill post when I find out what they say.

i had the same problem with my 03 6.0 and i replaced the tank and it don't leak anymore i did discover that the alum. peace at the end was pushed out a little.
Trent

I have the exact same problem. I think the EGR cooler is boiling the fluid out. I have stock guages and the temp guage and trans temp guage show normal yet coolent boils out of the resivuior. I run SCT with Spartan tunes on a stock motor (no studs) I know the head gaskets will blow so I have been taking it easy only hitting the horespower for very short runs. This has eliminated the coolent problem so I think you have the EGR cooler causing you to push coolent out. If this is not the problem then you are looking at the head gaskets.

my clutch fan starting coming on and staying on for long periods of time, come to find out my coolant res was low (not seeing any coolant) and i went to Ford for 2 gallons of the gold stuff, poured on gallon in like it was completely empty?? i have not heard it come on since filling it back up. i need to buy some studs and do an egr delete system on her.

Did you try doing a pressure test to the system or tank yet cause that might narrow it down a lil bit. :U:

ok this jsut summed up that I am keeping my 2 7.3's cause I hate the 6.4 and was thinking about a 6.0