I have a coolant leak from the oil cooler at the end where the oil filter goes. It is dripping from the bottom front. I removed the cooler and rebuilt it with all new gaskets and it still leaked. I removed it a second time and cleaned the mounting surface on the block with a wire wheel so that it was shiny clean. It's still leaking. Now what do I do? It seems to be leaking inside and then dripping out the bottom even though there does not appear to be any coolant in the oil. What do I do next? RTV sealant? This is so frustrating. This truck only has 36,000 miles on it so it's not like it's worn out.

 

Check the block very closely. There were some blocks that had a porosity problem where they could/would leak coolant out of fine holes in the casting. They were all right in that area.

 

If that is the case how would you go about fixing something like that?

 

Here is a link to the TSB on this issue.
Not sure if its a warranty issue or not
TSB 97-12-11 - 1994-1997 Power Stroke FAQ

 

Well now that's interesting stuff. I wonder if there is a way to verify that this is what my problem is? Thanks for the info.

 

Is there a way to tell when my engine was manufactured?

 

They specify build date of the truck
"VEHICLES BUILT FROM 9/1/95 THROUGH 10/31/95"
So look on the door sticker of the driver side and look in one of the corners for "Manufacture Date"

 

Looks like I drew the short straw this time. The sticker on the door shows 10/95

Do I need to start with the Ford dealer to have this fixed by Navistar or do I just contact them directly? It's not real clear to me in the TSB.

 

I would go to you local dealer with the printed out TSB that I linked. They will probably have to inspect it to see if that is where the leak is then I think they will handle contacting International. I do not know for sure if that is how it would work but that is how I would go about it.

 

I contacted the dealership where I bought it new. They had never heard of an instances where Navistar engineers would have to come on site to fix the problem. Also even if the diagnosis was exactly the issue mentioned in the TSB I would be responsible for all costs associated for the diagnosis and repair of this problem. At $95 an hour this would be one expensive leak to fix

 

I would call another dealer or even an International dealer. Its a manufacturer defect and I think should be covered but that doesn't mean much.