I've seen one do this before and it had munched a exhaust valve and cracked the head on the way out it was pretty incredible the amount of coolant that came out of that thing. Good that you found the problem though
You must have the patience of a Saint.. I would be doing some very horrible things to the guy who built that engine. Hope it all gets worked out man, my buddy has a knack for coming by cheap 7.3 longblocks if that can help you in any way.
Welcome from Kansas... If I had to do my 6.4 purchase all over again I would look for a low mileage truck that has been tuned and deleted irregardless of voiding the warranty. 09 and 10 trucks seem to have better luck than 08's. The prices are beginning to come down for a well taken care of xlt...
Pricey to fix... I bought mine with 160k on the clock, tuned and deleted it, 163k she dropped a lifter. They will put a smile on your face every time you stab the throttle but that all comes with a price tag when they grenade. I'd have looked a little harder at the one I bought I kinda made a...