I have a 2005 ford 6.0PSD, is the oil cooler failure and subsequent EGR replacement covered under the 100K warranty?

I would think so. Give your local Ford truck dealer a call. They will know and should welcome the business.

I would think so. Give your local Ford truck dealer a call. They will know and should welcome the business.

You were right grease monkey,they did take care of it, under warranty. Should I be concerned about the head gaskets after this volitile mixture was introduced into every nook and cranny in the engine?

Probably not. Start using full-synthetic HDDO in your PSD:

https://www.askmehelpdesk.com/cars-trucks/faq-how-troubleshoot-repair-maintain-hondas-selected-other-vehicles-46563-10.html#post1977241

The margin of safety is much higher, far fewer EGR and turbo problems, and better performance and longevity.