I've read several threads by searching and still haven't located what I want but I know it's in here. Since I can't seem to find a good independent mechanic locally who will do what I want to do, I guess after harvest I will begin to tackle it myself. My EGR and oil cooler need replaced on my 2005 6.0, so I will delete the egr and replace the oil cooler. I've heard horror stories about getting the turbo off, and I don't PLAN to remove the cab. Is there a step-by-step walkthrough of the process, including wrench / socket sizes and types and any special tools or surprises that commonly come up? I had a write up that went step by step for replacing injectors on my 7.3 along with the fuel bowl rebuild and all that, and I went through that painlessly and fairly quickly due to the good layout of the writeup, had all tools I would need set aside ready to go from the beginning and that made a big difference.

 

No need to remove the cab to get the turbo out. There are some tech's on here that can have it out in 15 minutes.

Virtually everything you want to fix or repair can be found in the 6.0 tech folder at the beginning of this forum.

 

Here is a link to srmastertechs youtube video showing commonly needed tools on the 6.0L,

 

I just did this on My truck, 3 10mm bolts to pedestal I had to use some heat on the one that is hidden on the driver side and used an hex socket for that, make sure to use anti seize later. The turbo doesn't "roll" to the pass side and out for Me so I used a pry bar (carefully!) to lift it up and out it came, plenty of space to get it out. V bands are 7/16" nuts, oil feed line I think are 5/16" and 10mm. Doesn't take very long but the one thing that was a hassle were the up pipes specially driver side You need 1/2" for the nuts and 10mm for the bolts head, problem is to fit the 10mm wrench, helps if You have long skinny arms.

 

https://www.ford-trucks.com/forums/1...many-pics.html

Rusty did some extra things (ie removing the hood) that aren't absolutely required, and showed more updates (STC fitting), but the pictorial is good. If it hasn't been done, the STC fitting is a cheap part for a lot of peace of mind, I'd highly suggest doing it at the same time.

A specialty tool for doing the up-pipe is a 10mm half moon wrench, I think it makes taking the pipes off the exhaust manifolds easier. Here's a write up on that part:
https://www.ford-trucks.com/forums/7...tructions.html

Search for "srmastertech" on youtube, and he has a video series that walks you through step by step:

Get down to where the intake is out, then before (or after, just probably not during) doing the oil cooler, pull out the y-pipe and up-pipe, pull the EGR cooler off the intake, and reverse.

 

The turbo is not that bad a flex head ratchet wrench does wonders. For the rear bolt a 4" ext. 10mm and 1/4 ratchet and you can get the rear bolt from the top with no issues. I would recommend if it hasn't been done to replace your STC fitting while you have it torn down. It is another $50 bucks but when they fail your done running until it's replaced. You will be about 12 bolts away from it and have everything out of the way while doing the delete. I just did mine just so I have one less thing to worry about. Oh and the blue hose on the egr cooler just turn and push it will slide.

 

OIL COOLER REBUILD INFO
TURBO REMOVVAL
https://www.ford-trucks.com/ford-man...%20Removal.pdf
INTAKE MANAFOLD REMOVAL
https://www.ford-trucks.com/ford-man...%20removal.pdf
OIL COOLER REMOVAL
https://www.ford-trucks.com/ford-man...er_Removal.pdf
OIL COOLER NAVSTAR
https://www.ford-trucks.com/ford-man...20Navistar.pdf
OIL COOLER REPAIR
https://www.ford-trucks.com/ford-man...r%20Repair.pdf

 

It may take you longer to go threw all the Links and Videos in this thread then to do the Job LOL

Thuro for shure Great Job Guys

 

Double post sorry

 

Would Also be a Good Idea to Flush your Cooling system and ADD A Coolant filter Proir to the Work

I flushed mine 3 times prior to a New Oil Cooler and Ran a Coolant filter for about 6-7K before I changed the Oil Cooler

Iv got about 25K Since and the Oil Cooler is as good as the day it was New

 

Overall I like DieselTechRon's videos better...

DieselTechRon - YouTube

Srmastertech does an excellent job, however, he does remove and take a lot more steps than needed on a lot of repairs.

Josh