Oil cooler replacement woes

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Jul 26, 2011 | 09:53 PM

Sheryle

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Oil cooler replacement woes

I spent most of the afternoon digging down to my oil cooler. Read the shop manual and lots of threads here before I started so I had a fair handle on the procedure. Two plus years back I had the truck in a local "reputable" diesel shop for head studs, gaskets and EGR delete. The shop has an A+ BBB rating. I was not expecting what I found. First when I removed the FICM I find the electrical connections trashed. The plastic clips and covers were broken in several places. I have never had any issues or problems with the FICM. I've checked voltage 2-3 times and it was good. Next the turbo had only one bolt holding it in place. No bolt in the rear or passenger side. I can handle the missing bolts. Just put three in when I put it back together. My problem is the wiring harness. When I turned it over to unplug it, the center plug fell loose the outside plugs were a b...h to remove because the clips or parts of the clips were broken. So when I start putting it back I don't know if it will hold or not. Does anyone have a suggestion short of replacing each harness. Buying the cooler kit and gaskets was tough enough. I really don't need to spend any more than I absolutely have to. Thanks for reading.

Jul 27, 2011 | 04:15 AM

npccpartsman

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Joined: Dec 2003

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From: Stuttgart, Ar

Turbo bolts, unfortunately, can fall out on their own. As far as the FICM harness goes, If it's just the clips on the on the plugs broken, once you get it plugged back up you can wrap a big tie strap all the way around the FICM and each harness plug-in and hold them in. I know that sounds ghetto but it works very well. Those get broken often because they seal very tightly and are HARD to unplug for some folks. As long as the plugs and pins are in good shape you'll be OK.