75,000 miles: Ran rough; Injector, glow plug, and glow plug relay all replaced (warranty).
85,000 miles: Ran rough and white smoke from exhaust at cold start; Injector, glow plug, and glow plug relay replaced (warranty).
90,000 miles: T-case wouldn't shift; Rebuilt with new shaft, cluster gear and shift fork. $850. Also, parking brake cable broke. $60.
97,000 miles: Ran rough and white smoke from exhaust at cold start; Two injectors and a glow plug relay replaced (warranty).
115,000 miles: Motor cuts out; Camshaft position sensor replaced. $89 ($212 from Ford.)
120,000 miles: Ran rough and white smoke from exhaust at cold start; replaced three injectors, glow plug relay and air box. $2100.
128,000 miles: Clutch would not disengage; replaced master and slave cylinders, clutch and refitted transmission input shaft for new pilot bearing. $1100.
Good looking truck. Good ride - handles well for a 3/4 ton pick-up. Fairly comfortable. Okay fuel mileage. Expensive to maintain.
This was the first year of the new Super-Duty body style. The transfer case problem was due to a thin shift fork. Ford changed the design of this and the related parts, but I don't know what year they started the change.
The camshaft positions sensors are prone to failure. Ford wants over $200 for this part. International sells the same part for less than $100. It's not a bad idea to keep a spare in your glove box because it can go out all at once leaving you completely stranded -- you just need a 10mm wrench to change it.
Our latest mechanic said the problem with the multiple fuel injector failures is not typical and was caused by a small break in the air box that allowed the engine to aspirate unfiltered air. This was not a Ford mechanic. The Ford mechanics that did the warranty work did not noticed the broken air box. Actually, I wouldn't be surprised if they didn't break it themselves.
I'm horrified by Ford's mechanics, their cavalier attitude toward customer service and their parts prices. They did an okay job of getting the truck into the bay, but the mechanics failed to find what was causing the problem. This and the parts prices will be the reason I will not buy a Ford product again -- at least not if it's under warranty and not unless there's a substantial supply of aftermarket parts for the vehicle.
Overall, I really like this truck. It has been really hard on our budget though. I enjoy driving it, but I do not find the driver's seat comfortable for long trips. It tows well, especially with the 6-speed manual; but it's not the best for hauling the really heavy trailers. I get 14-15 MPG highway and 15-16 with the tailgate off (at 70-80 MPH). Towing a 7000 pound trailer, it gets about 12 MPG.