Fulltext TSBs

Technical Service Bulletins

TSB
09-18-12
  • COOLING SYSTEM DIAGNOSTICS – OIL IN ENGINE COOLANT – 6.0L
Publication Date: September 8, 2009

FORD:
2003-2005 Excursion
2003-2007 F-Super Duty
2004-2009 E-Series

This article supersedes TSB 07-23-14 to update the Issue Statement, Service Procedure and Part List.

ISSUE:

Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2009 E-Series vehicles equipped with a 6.0L engine, may exhibit oil contamination into the cooling system due to an internally leaking oil cooler heat exchanger.

ACTION:

Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

NOTE:ONLY USE THIS PROCEDURE IF OIL IN COOLANT IS VERIFIED, EGR COOLER WILL BE INSPECTED FOR INTERNAL LEAKS DURING OIL COOLER SERVICE.

  1. Replace the oil cooler heat exchanger following Workshop Manual (WSM), Section 303-01 Removal and Installation, Oil Cooler, and Disassembly and Assembly, Oil Cooler, instructions.

    NOTE:ENSURE THAT THE OIL RESERVOIR IS CLEAN OF ANY DEBRIS AND THAT THE SCREEN AT THE BOTTOM OF THE RESERVOIR IS NOT DAMAGED.

    NOTE:LEAKING OIL COOLERS ARE FREQUENTLY CAUSED BY RESTRICTED COOLANT PASSAGES WITHIN THE OIL COOLER HEAT EXCHANGER. THESE RESTRICTIONS CAN ALSO CAUSE DAMAGE BY OVERHEATING THE EGR COOLER.

  2. Prior to reassembly, remove and check the EGR cooler for leaks using the 2008 6.4L F-Super Duty or LCF EGR cooler block off adapters.

    NOTE:A DEFECTIVE EGR COOLER CAN CAUSE COOLANT TO VENT OUT OF THE DEGAS BOTTLE AND APPEAR SIMILAR TO HEADGASKET FAILURE.

    1. Remove the EGR cooler from the engine following WSM, Section 303-08.
    2. Install block off adapters using standard screws and washers. (Figure 1)


      Figure 1 – Article 09-18-12

    3. Install shop air adapter and regulator and pressurize cooler to 30 psi (207 kPa). Listen for leaks.

      NOTE:FOR VERY SMALL LEAKS, IT MAY BE REQUIRED THAT EGR COOLER REMAIN SUBMERGED FOR UP TO 15 MINUTES TO AID IN LEAK IDENTIFICATION. THIS TIME IS NEEDED TO ALLOW SMALL LEAKS TO DISPLACE ENOUGH WATER FROM THE COOLANT PASSAGES TO BECOME EVIDENT.

    4. Submerge the EGR cooler horizontally in the water, with the coolant ports pointing upward. Manipulate the cooler under water to purge all trapped air from the internal coolant passages. (Figure 2)


      Figure 2 – Article 09-18-12

    5. Inspect for continuous bubbles escaping from the coolant ports.
      1. If continuous bubbles identify a leak, replace the EGR cooler. Proceed to Step 3.
      2. If bubbles do not identify a leak, do not replace the EGR Cooler. Install and proceed to Step 3.
  3. Flush cooling and heater system together using the latest service procedure. Refer to other applicable articles.
  4. Use Radiator Refiller tool to fill cooling system. Refer to WSM, Section 303-03.
  5. Replace the degas bottle pressure cap due to oil contamination.
  6. Change engine oil and oil filter.

PART NUMBERPART NAME
3C3Z-9P456-AEEGR Cooler (Built Before 9/29/2003)
4C3Z-9P456-AFEGR Cooler (Built 9/29/2003 And After)
3C3Z-6A642-CAOil Cooler Kit
9C3Z-8101-ACap – Degas Bottle

OTHER APPLICABLE ARTICLES:

05-2-5,  08-23-1

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATIONDESCRIPTIONTIME
091812A2003 F-Super Duty, Excursion 6.0L: Install The Oil Cooler Kit Includes Time To Test And Replace The EGR Cooler If Necessary, And Change The Oil And Filter (Do Not Use With 6642A, 9456A, 9424A, 9600A, 8005A, 9438A)5.7 Hrs.
091812A2004-2007 F-Super Duty, 2004-2005 Excursion 6.0L: Install The Oil Cooler Kit Includes Time To Test And Replace The EGR Cooler If Necessary, And Change The Oil And Filter (Do Not Use With 6642A, 9456A, 9424A, 9600A, 8005A, 9438A)6.1 Hrs.
091812A2004-2009 Econoline 350/450/550 6.0L: Install The Oil Cooler Kit Includes Time To Test And Replace The EGR Cooler If Necessary, And Change The Oil And Filter (Do Not Use With 6642A, 9456A, 9424A, 9600A, 8005A, 9438A)7.9 Hrs.

DEALER CODING

BASIC PART NO.CONDITION CODE
6a64255