It is probably the standard 2004 headaches, EGR valve failure, turbo failure, injector o-ring failure, poor programming, or crankcase full of fuel oil. Oh yeah, also add clock spring generator broken, leaking rear differential (both ends,) lack of power, and head lights flicker on high beam. All in less than 29,000 miles. LEMON LAW IT!!! When has Ford ever discontinued or completely redesigned an engine in 3.5 years? Ever drive an International truck with a VT 365 in it? It is the same engine, minus Ford's tweaking. International doesn't have any problems with their version of the engine. It has much more power than my '04 drw, 4.10 gears. Both have a five speed auto, same gear ratio. Why so much more power from an engined rated for 230 hp and 540 ft.lbs torque? Hire a good attorney and get your money back. The 6.0 was doomed when Ford's engineers touched it. Hopefully they learned their lessons on the 6.4. Don't think International will let Ford stick it to them again. They did it with the 4.5 v6 diesel also (slated for the F150.) Watch for the lawsuits to follow. They are already in the making.