I know I would not be a fan of Ford if I spent $50,000+ on a truck, only to have to pony up several thousand more dollars to replace poorly engineered parts.
It would save them a serious beating on their reputation as well as more money down the road fixing them.
You mentioned them having the body off, they have to do that to get to the turbos and everything else because they packed it so tight. Removal of the heads to replace the head bolts, which are apparently a commonly failing component, requires removing the body.
As far as the problems with the engines, most of them come down to physics - they're trying to make more power with a smaller engine.
The loss of displacement means they have to run higher compression, more boost and higher RPMs, which in turn means higher pressures and temperatures.
Combine that with the absolute minimum amount of metal necessary to hold the engine together under normal conditions to save money (bean counters) and weight (fuel economy) and you end up with a bomb waiting to go off.
The emissions equipment just adds another, separate dimension to the complexity and potential problems.
What I've read is that they supposedly couldn't economically redesign the 7.3 to meet the new emissions requirements.
My guess is that they probably could have redesigned the top end of the 7.3 (which is what is most effect by the emissions requirements) for as much or less than what they've probably spent on the 6.0, 6.4 and now the 6.7 and all of their various problems.
But, we all know that newer is ALWAYS better...
Ah, the nostalgic aroma of a yak dung stove brewing up some tea full of herbs best left untranslated.
From the Zen Backpacking Site
It was 101400 miles when the intercooler blew up and that was the second time it had stranded me on a camping trip. I was really tired of it, and figured it was a matter of time before I was really into some money. It had run flawless for 99999 miles. I figured my good fortune had run out. I bought an 08 duramax in Boise on a saturday at 8:00PM with my 30' toy hauler sitting in the parking lot. funny story was the saleman talking about the 500 mile break in on the ceramic bearings on the rearend before you tow with it. I asked if the warranty was void if i didn't wait 500 miles. he said no. I said it sounded like his problem, and took off towing 23K pounds out of the parking lot.
I long for the days when a guy could go put combine parts on a cummins 5.9 and get 23-26 MPG and nobody wanted to stick a sniff sensor up his exhaust pipe. Same goes for the old 7.3. I am so done with the new stuff.
I am taking some advise that UH keeps throwing at us younger members. I have unloaded all of my toys and i am also unloading the 08 duramax. It only has 34K on it and is worth a quite a bit of $$. We can work toward being debt free instead of working for the man. I have a chev 1500 4x4 company truck that I can use for whatever I want. If I need to use a big truck, I just need to borrow another company truck for a weekend. Getting too old to be working this hard. It helps that we will be empty nesters in 2014. awsome!!
For a while it was cool to buy & sell every cpl years with the $25k tax credit for HOV work vehicles...that needs to go back into effect before my wife needs another vehicle.
I love Toyotas - IMHO, consistently the most reliable, least repaired vehicles out there. My best buddy drives a Tundra and never puts any repair money into it, just routine maintenance.
Tundras are 75% made of American parts so I don't know how much it matters whether you buy a US or foreign nameplate.