Not including normal wear items:
Torque converter failed $350
Alternator failed twice.
Leaf spring brackets rusted and failed ($675)
Starter
Oil pan gasket ($130)
Radiator (twice)
Exhaust (4 times $400+ each time)
Throttle body gasket
Headlight switch
Wiper motor
Transmission shift rod
Fuel pressure regulator
Brake lines ($395)
Power steering lines ($195)
Radius arm bushings ($275)
Heater switch.
These items have been diagnosed as bad and are due for repair/replacement.
Water pump.
Oil pan.
Motor mounts.
Exhaust manifold.
Rear gas tank leaks.
I bought this truck brand new and it has served me well.
Pro's:
Tough as advertised. Regularly towed a 6000Ib travel trailer long distances. Occasionally hauled a truck camper. Suspension and tranny has held up much better than expected.
Comfortable bench seat.
Visibility excellent.
Ventilation excellent (love those vent windows)
Well though out interior. Controls and switches generally reliable.
Reliable engine. To this day its running like new and uses no oil.
Ease of maintenance very good. Plenty of room to work in the engine bay.
Con's:
Performance poor. The straight six engine does fine around town, but is a slug on the highway. Go for a bigger engine if you plan on towing.
Fuel economy Poor: 18-20 highway. 16-17 highway in the winter.
Handling less than average: Gets quite bouncy unloaded, but the ride smooths out nicely once loaded. This truck likes to work.
Overall reliabilitiy less than average: This is not a Honda or Toyota so there will be problems over time. Some repairs were quite expensive. Almost all of the problems I had were not due to towing/hauling abuse, but were design issues that were outlined under Ford released TSB's and recalls.
Dealer service poor: Reluctant to perform warranty work causing unnecessary hassles for me. Rudeness seems to be common place in the dealer service department. I don't feel like a customer there (more like cattle) but from what I understand this is not limited to Ford. Learn to perform repairs yourself or find an independent mechanic you can trust.
You paid a Lot for your Leaf Spring Work. I managed to find Both Sides for my 1993 F-150 Lariat at a local Wreckers Yard for $150.All I had to do was blow them out with an Air Compressor and Gloss Black them over. I would shop around a bit more if I were you.