Don't guess on exhaust temps.....install a pyro so you know what they are.
Your temps will prolly be fine with the economy tune, but I personally like to know exactly what my temps are.
To answer your second question, while you don't have to upgrade the exhaust, it sure wouldn't hurt a thing...
Ford must be a big fan of it because they contracted BG to make the kit for them.
Have you used the BG tool to clean up the EGR system?
As far as paying for the service most of the ones we do are because they are outta warranty now.
Find a shop that uses BG products and have them do the EGR service on your 6.0l. It'll make the truck run like new. I use this system at work and it's awesome, IT WORKS. This site will tell you if there is a shop near you.
http://www.bgfindashop.com/locator/index.php
Since I know nothing about your mechanical knowledge or abilities I would suggest that you might want to consider taking the vehicle to a AAA approved shop, they can do a buyers check out on this vehicle for 89.95 and it is real in depth and will give you peace of mind when purchasing a used...
Perhaps it's a problem with the blower resistor. Some of those will melt the connectors. In fact I found a truck the other day that the blower wasn't working properly and the dealer had put and updated harness from the ignition switch to the blower motor.
I use a kit very similar to that one and it works damn good. Done properly it makes for a VERY GOOD repair. Even used it on a Taurus the other day with great results..;Sweet
You will see coolant leaking from one of the 4 corners of the intake.
I have never seen any kind of a performance problem because the coolant leaks to the outside of the intake and not internally.
Added in edit: It is possible for it to leak internally but it is VERY rare that, that happens.
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