I have a 04 f250 6.0, yesterday I was changing out the oil sending unit, got it out ok but when I was putting in the new one I was tightening it down and it never seemed like it was getting tight. I pulled it back out and noticed what looked like the threads of inside the hole on the threads of the oil sending unit. My question is in that hole on the intake manifold is that a tapped hole or is there a helicoil in there, and what size hole, is it fixable?

 

If it wasn't a helicoil before, it is now. Don't worry people do this all the time. Got to remember they are only aluminum threads!!

 

How do I fix it

 

Get a helicoil kit for the size thread you need. Example if it was a 1/4-20, you get a repair kit for a 1/4-20. It usually comes with a tap, heli coils and an install tool. You will need to buy the correct size drill bit for it plus the kit.

 

What about the shavings from drilling and tapping, what if they get down in the hole?

 

That hole is not in the intake manifold. It is in a part called the oil filter adapter. Worst case scenario is if it needs replaced, it can be purchased but requires intake manifold removal to access and replace.

 

Here is a thread insert kit, may be a little easier to seal the outside than a helicoil.
Here is a heli coil kit, but with it being straight threads and an oring on the sending unit, I think you would have a hard time sealing between the helicoil and the block.

 

Run the drill slow and coat the bit and tap with alot of grease. Clean several times. The AL shavings will stick to the grease. Replacement would be best, or remove and install an insert.

 

Removal would include taking off the intake I see. So basically everything on top including the turbo correct?

 

Also there is a metal rod that comes off the turbo right in the way down there, can that be removed for better access?

 

The oil pressure sending unit is 7/16" bolt thread.

 

If you're referring to the oil supply line, it bolts top and bottom, just be careful with the gasket on top of the turbo.

 

Thanks for the info, saves a little time already knowing

 

I think so, I know at the bottom down by the oil sending unit it only has one bolt, is that the one? If so, so it bolts to the top of the turbo also?

 

That would be it. 8mm socket bottom 10mm gearwrench on top zips that baby right on out.