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2005-07 F-SuperDuty/Excursion No-Start, High Pressure Oil System Leak:
Some trucks may develop an oil leak at the high pressure oil pump outlet fitting. This will cause a no-start condition as the computer needs to see at least 500 PSI before it will activate the injectors. In some cases the no-start will be intermittent and/or an intermittent stall with no codes will occur. If high pressure oil leak diagnosis indicates a leak at the pump, the pump outlet fitting (W301727) and the discharge tube block should be replaced with fitting and bracket kit 4C3Z-9B246-A. Do not torque the outlet fitting beyond 38 ft/lbs. If the leak is traced to the branch tube running through the engine block, replace with P/N 5C3Z9J332-B (requires removal of the transmission, flywheel and rear engine cover; new flywheel bolts required). TSB 06-14-6.
The following bulletin may be related:
Metal Tapping Noise from Rear of Engine:
Excursions built after 1-10-05 and 2005/06 F-SuperDuty may have a metal tapping noise from the rear of the engine on decel or light acceleration, or under loads when the high oil pressure is at higher levels. This may be due to a damaged/improperly fitting HP oil pump output quick connect fitting. To diagnose, you will need a scan tool with active command capability. Command the IRP duty cycle to 45% and listen at the high pressure oil pump cover with a stethescope as the engine speed is increased to 2800 RPM. If the noise is louder on the pump cover than on other parts of the engine, the pump cover will need to come off to inspect and replace the fitting. Broadcast Message 5511.
Sounds to me like the rail is losing its prime. Read this Technical Service Bulletin from Ford:
Unfortunately, because the 6.0's HPOP system is located in the back of the engine, the cab will need to be pulled for this repair. IT sounds like he hasn't gotten to this stage yet, but more than likely he is getting there. Eventually he may very well end up with a no start condition.
I was reading about an oil additive that may clean out some deposits in HPO system possibly.