Fulltext TSBs

Technical Service Bulletins

TSB
05-13-5
  • OIL LEAK OR BOOST PRESSURE LEAK AT HOT SIDE CHARGE AIR COOLER (CAC) DUCT – 6.0L DIESEL ENGINE
Publication Date: June 17, 2005

FORD:
2003-2005 Excursion
2003-2006 F-Super Duty

ISSUE:

Some 2003-2005 Excursion and 2003-2006 F-Series Super Duty vehicles equipped with the 6.0L diesel engine, may exhibit an oil leak or boost pressure leak at hot-side charge air cooler (CAC) duct assembly connections.

ACTION:

The hot-side CAC duct is no longer available as an assembly. Should CAC repairs become necessary, individual components must be ordered to rebuild the duct assembly. Refer to the following Service Tips.

SERVICE TIPS

  1. Carefully inspect all components, and order only the components needing replacement.
  2. Thoroughly clean all components to be reused, especially in the joint clamp areas as well as the turbo and CAC connections.
  3. If the curved turbo hose must be replaced, mark the metal duct adjacent to the faint white alignment mark on the old hose (top position in vehicle) before removing it from the duct. Then install the new hose so its alignment mark is adjacent to the mark made on the metal duct.
  4. Carefully reinstall the rebuilt duct assembly. Torque all four (4) clamps to 9 lb-ft (12 N-m) only, over tightening will damage the component.

PART NUMBERPART NAME
6C2Z-6K786-AAClamp
6C3Z-6K786-CAClamp
5C3Z-6C640-AATurbo Hose – Shorter
5C3Z-6C640-BATurbo Hose – Longer
YC3Z-6C640-KACAC Hose
5C3Z-6K769-BAMetal Duct – Dual Generator
3C3Z-6K769-CAMetal Duct – Dual Generator
5C3Z-6K769-AAMetal Duct – Single Generator
3C3Z-6K769-DAMetal Duct – Single Generator

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

DEALER CODING

BASIC PART NO.CONDITION CODE
6C64642