Oil Cooler Failure! Help!
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Junior User
Joined: Jan 2011
Posts: 73
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Oil Cooler Failure! Help!
The Oil Cooler on my 04 F-350 6.0 Power Stroke decided to fail today. I had it towed to a local dealer to have it diagnose and see what needs to be done to get it running again. They tole me I need to replace the Oil Cooler, Radiator, EGR Cooler, Modulator Valve, Recovery Tank, Thermostat and all hoses, as well as flush out the block. The grand total for these repairs are Labor $2,600 and Parts $2,850.
Obviously I don't have any where near that amount to throw into my truck right now, so I am trying to figure out what definitely needs to be replaced, and what I can clean out and reuse. Any Suggestions on what I can try or what I could upgrade when I replace to prevent this from happening again.
Here is a list f the parts they told me I need:
3C3Z6A642BB - OIL COOLER KIT - $583.33
4C3Z9P456AH - EGR COOLER - $488.17
4C3Z9F452A - MODULATOR VALVE ASSEMBLY - 230.77
FL2016 - ELEMENT & GASKET KIT - $29.00
3C3Z6766CA - CAP ASSEMBLY - OIL FILLER - $28.93
6C3Z8A080B - RADIATOR OVERFLOW TANK - $73.67
9C3Z8101B - RADIATOR CAP W/ PRESS - $10.88
4C3Z8009AA - RADIATOR ASSEMBLY - $764.52
3C3Z8075AD - SUPPLY TANK HOSE - $21.92
3C3Z8075AE - HOSE ASSEMBLY - $62.29
3C3Z9Y439AD - HOSE ASSEMBLY - $22.00
3C3Z18472BC - WATER HEATER HOSE - $40.98
5C3Z18472F - WATER HEATER HOSE - $75.91
3C3Z8260AG - HOSE ASSEMBLY - $34.51
5C3Z8286A - HOSE ASSEMBLY - $81.18
3C3Z8575AA - THERMOSTAT ASSEMBLY - $31.37
3C3Z8255AA - GASKET - $5.70
Obviously I don't have any where near that amount to throw into my truck right now, so I am trying to figure out what definitely needs to be replaced, and what I can clean out and reuse. Any Suggestions on what I can try or what I could upgrade when I replace to prevent this from happening again.
Here is a list f the parts they told me I need:
3C3Z6A642BB - OIL COOLER KIT - $583.33
4C3Z9P456AH - EGR COOLER - $488.17
4C3Z9F452A - MODULATOR VALVE ASSEMBLY - 230.77
FL2016 - ELEMENT & GASKET KIT - $29.00
3C3Z6766CA - CAP ASSEMBLY - OIL FILLER - $28.93
6C3Z8A080B - RADIATOR OVERFLOW TANK - $73.67
9C3Z8101B - RADIATOR CAP W/ PRESS - $10.88
4C3Z8009AA - RADIATOR ASSEMBLY - $764.52
3C3Z8075AD - SUPPLY TANK HOSE - $21.92
3C3Z8075AE - HOSE ASSEMBLY - $62.29
3C3Z9Y439AD - HOSE ASSEMBLY - $22.00
3C3Z18472BC - WATER HEATER HOSE - $40.98
5C3Z18472F - WATER HEATER HOSE - $75.91
3C3Z8260AG - HOSE ASSEMBLY - $34.51
5C3Z8286A - HOSE ASSEMBLY - $81.18
3C3Z8575AA - THERMOSTAT ASSEMBLY - $31.37
3C3Z8255AA - GASKET - $5.70
Senior User
Joined: Feb 2005
Posts: 113
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The Oil Cooler on my 04 F-350 6.0 Power Stroke decided to fail today. I had it towed to a local dealer to have it diagnose and see what needs to be done to get it running again. They tole me I need to replace the Oil Cooler, Radiator, EGR Cooler, Modulator Valve, Recovery Tank, Thermostat and all hoses, as well as flush out the block. The grand total for these repairs are Labor $2,600 and Parts $2,850.
Obviously I don't have any where near that amount to throw into my truck right now, so I am trying to figure out what definitely needs to be replaced, and what I can clean out and reuse. Any Suggestions on what I can try or what I could upgrade when I replace to prevent this from happening again.
Here is a list f the parts they told me I need:
3C3Z6A642BB - OIL COOLER KIT - $583.33Can get this for 214.00 from Tousley
4C3Z9P456AH - EGR COOLER - $488.17 Can get this for around 350. from Sinister
4C3Z9F452A - MODULATOR VALVE ASSEMBLY - 230.77
FL2016 - ELEMENT & GASKET KIT - $29.00 18.00 from Walmart
3C3Z6766CA - CAP ASSEMBLY - OIL FILLER - $28.93
6C3Z8A080B - RADIATOR OVERFLOW TANK - $73.67
9C3Z8101B - RADIATOR CAP W/ PRESS - $10.88
4C3Z8009AA - RADIATOR ASSEMBLY - $764.52
3C3Z8075AD - SUPPLY TANK HOSE - $21.92
3C3Z8075AE - HOSE ASSEMBLY - $62.29
3C3Z9Y439AD - HOSE ASSEMBLY - $22.00
3C3Z18472BC - WATER HEATER HOSE - $40.98
5C3Z18472F - WATER HEATER HOSE - $75.91
3C3Z8260AG - HOSE ASSEMBLY - $34.51
5C3Z8286A - HOSE ASSEMBLY - $81.18
3C3Z8575AA - THERMOSTAT ASSEMBLY - $31.37 20.00 from Tousley
3C3Z8255AA - GASKET - $5.70
Obviously I don't have any where near that amount to throw into my truck right now, so I am trying to figure out what definitely needs to be replaced, and what I can clean out and reuse. Any Suggestions on what I can try or what I could upgrade when I replace to prevent this from happening again.
Here is a list f the parts they told me I need:
3C3Z6A642BB - OIL COOLER KIT - $583.33Can get this for 214.00 from Tousley
4C3Z9P456AH - EGR COOLER - $488.17 Can get this for around 350. from Sinister
4C3Z9F452A - MODULATOR VALVE ASSEMBLY - 230.77
FL2016 - ELEMENT & GASKET KIT - $29.00 18.00 from Walmart
3C3Z6766CA - CAP ASSEMBLY - OIL FILLER - $28.93
6C3Z8A080B - RADIATOR OVERFLOW TANK - $73.67
9C3Z8101B - RADIATOR CAP W/ PRESS - $10.88
4C3Z8009AA - RADIATOR ASSEMBLY - $764.52
3C3Z8075AD - SUPPLY TANK HOSE - $21.92
3C3Z8075AE - HOSE ASSEMBLY - $62.29
3C3Z9Y439AD - HOSE ASSEMBLY - $22.00
3C3Z18472BC - WATER HEATER HOSE - $40.98
5C3Z18472F - WATER HEATER HOSE - $75.91
3C3Z8260AG - HOSE ASSEMBLY - $34.51
5C3Z8286A - HOSE ASSEMBLY - $81.18
3C3Z8575AA - THERMOSTAT ASSEMBLY - $31.37 20.00 from Tousley
3C3Z8255AA - GASKET - $5.70
Junior User
Joined: Jan 2011
Posts: 63
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The price on the oil cooler itself is high. You can buy one from Tousley Ford Parts depot for 213.00 and it comes with all the gaskets for it. You can also buy a kit from Throughbred diesel .com for 665.00. It comes with the oil cooler, gaskets, and egr delete. I'm not sure about the radiator and all the hoses. If you have any mechanical ability you can do it your self. Do a search for oil cooler replacement and you will find guys who have done it and directions to do it.
Thread Starter
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Junior User
Joined: Jan 2011
Posts: 73
Likes: 0
Thanks for the links to the cheaper prices. I do plan on doing the work myself, although I don't really have the time for it I have no choice. I hoping I can just flush the radiator and reuse it, but ill have another mechanic look at that before i do. What are the advantages to putting on an egr delete? Also I have seen people mention using an upgraded oil cooler. Any suggestions on where I can get one thats worth the while?
Thread Starter
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Junior User
Joined: Jan 2011
Posts: 73
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Yeah I didn't we have 50 gallon barrels of that and the oil for our tractors on the farm so that wont cost me anything extra.
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Cargo Master
Joined: Feb 2002
Posts: 2,414
Likes: 22
From: Tucson USA
mine didnt blow but I just had mine R&Rd. There is a TSB on cleaning the system so I dont know why you would need to R&R the rad and all that is related. What you do need to consider probably is putting in new headstuds and gaskets. Bismic and some of the others are very knowledgeable and can help with some stuff I am sure. I got headstuds related gaskets, Bullit proof diesel egr, new oem oil cooler and all new TSB stuff and paid just under $4K installed. Also went with the caterpillar ELC coolant, new fan belts all the normal stuff while it was in for repair and stuff was loose.
Also plan to add an coolant filter for the truck buy a kit for around $100 or make up your own for a little less. Look at he links on building up a solid motor. There is a good link and discussion on powerstroke.org I think it is. Look up the TSBs here at the top of the page and they will detail how to do things you will need to do.
Also plan to add an coolant filter for the truck buy a kit for around $100 or make up your own for a little less. Look at he links on building up a solid motor. There is a good link and discussion on powerstroke.org I think it is. Look up the TSBs here at the top of the page and they will detail how to do things you will need to do.
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Thread Starter
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Junior User
Joined: Jan 2011
Posts: 73
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I'll look into the headstuds and baskets. I was already thinking of puttig in a coolant filter too. I just recently had the truck in for service and while ig eas in I already had all the belts and pulleys checked and replaced. I will replace the water pump while I have everything apart since the truck is pushing 200k on the odometer. Do you have any links to the discussion you were referring to?
Hotshot
Joined: Dec 2003
Posts: 15,368
Likes: 121
From: Stuttgart, Ar
The Oil Cooler on my 04 F-350 6.0 Power Stroke decided to fail today. I had it towed to a local dealer to have it diagnose and see what needs to be done to get it running again. They tole me I need to replace the Oil Cooler, Radiator, EGR Cooler, Modulator Valve, Recovery Tank, Thermostat and all hoses, as well as flush out the block. The grand total for these repairs are Labor $2,600 and Parts $2,850.
Obviously I don't have any where near that amount to throw into my truck right now, so I am trying to figure out what definitely needs to be replaced, and what I can clean out and reuse. Any Suggestions on what I can try or what I could upgrade when I replace to prevent this from happening again.
Here is a list f the parts they told me I need:
3C3Z6A642BB - OIL COOLER KIT - $583.33 $213
4C3Z9P456AH - EGR COOLER - $488.17 bulletproof or delete it
4C3Z9F452A - MODULATOR VALVE ASSEMBLY - 230.77 Only if the EGR valve is failed
FL2016 - ELEMENT & GASKET KIT - $29.00 your choice
3C3Z6766CA - CAP ASSEMBLY - OIL FILLER - $28.93 ridiculous
6C3Z8A080B - RADIATOR OVERFLOW TANK - $73.67 only if it's failed
9C3Z8101B - RADIATOR CAP W/ PRESS - $10.88 definitely
4C3Z8009AA - RADIATOR ASSEMBLY - $764.52 less than $300
3C3Z8075AD - SUPPLY TANK HOSE - $21.92
3C3Z8075AE - HOSE ASSEMBLY - $62.29
3C3Z9Y439AD - HOSE ASSEMBLY - $22.00
3C3Z18472BC - WATER HEATER HOSE - $40.98
5C3Z18472F - WATER HEATER HOSE - $75.91
3C3Z8260AG - HOSE ASSEMBLY - $34.51
5C3Z8286A - HOSE ASSEMBLY - $81.18
3C3Z8575AA - THERMOSTAT ASSEMBLY - $31.37 Motorcraft RT-1169 comes with the gasket
3C3Z8255AA - GASKET - $5.70 comes with thermostat
Obviously I don't have any where near that amount to throw into my truck right now, so I am trying to figure out what definitely needs to be replaced, and what I can clean out and reuse. Any Suggestions on what I can try or what I could upgrade when I replace to prevent this from happening again.
Here is a list f the parts they told me I need:
3C3Z6A642BB - OIL COOLER KIT - $583.33 $213
4C3Z9P456AH - EGR COOLER - $488.17 bulletproof or delete it
4C3Z9F452A - MODULATOR VALVE ASSEMBLY - 230.77 Only if the EGR valve is failed
FL2016 - ELEMENT & GASKET KIT - $29.00 your choice
3C3Z6766CA - CAP ASSEMBLY - OIL FILLER - $28.93 ridiculous
6C3Z8A080B - RADIATOR OVERFLOW TANK - $73.67 only if it's failed
9C3Z8101B - RADIATOR CAP W/ PRESS - $10.88 definitely
4C3Z8009AA - RADIATOR ASSEMBLY - $764.52 less than $300
3C3Z8075AD - SUPPLY TANK HOSE - $21.92
3C3Z8075AE - HOSE ASSEMBLY - $62.29
3C3Z9Y439AD - HOSE ASSEMBLY - $22.00
3C3Z18472BC - WATER HEATER HOSE - $40.98
5C3Z18472F - WATER HEATER HOSE - $75.91
3C3Z8260AG - HOSE ASSEMBLY - $34.51
5C3Z8286A - HOSE ASSEMBLY - $81.18
3C3Z8575AA - THERMOSTAT ASSEMBLY - $31.37 Motorcraft RT-1169 comes with the gasket
3C3Z8255AA - GASKET - $5.70 comes with thermostat
LOL--I didn't see KY jelly on that list for what they're giving you.
Do you know if your 04 truck has an 03 or 04 motor? It will make a difference on the EGR cooler and possibly the oil cooler assy. depending on the turbo lines. An easy way to tell is if the ICP sensor is in the passenger side valve cover it's an 04 motor or if the truck is made before 9/29/03 it SHOULD be an 03 motor.
Hotshot
Joined: Dec 2003
Posts: 15,368
Likes: 121
From: Stuttgart, Ar
Which is probably the reason for they want to charge him for a complete oil cooler assy. I would think it's cheaper to convert to a late model setup and would also probably mean that his EGR cooler hasn't failed.
Fleet Mechanic
Joined: Jan 2007
Posts: 1,708
Likes: 7
From: Circle City
Xsportplyer,
If you can do the work yourself and buy the parts, the oil cooler should be around $215, a Vc-9 flush @$50, EGR delete kit around $150,... it's not that difficult of a job to do, it just takes a little more time than other like jobs since the coolers are buried you have to remove a few extra components.
The bright side is getting to know your vehicle a lot better while addressing other mods you might want to do while you're in there... AND you will always have heaps of help from FTE members to walk you through any "unchartered territory" under the hood saving you over $100/hr shop time.
If you can do the work yourself and buy the parts, the oil cooler should be around $215, a Vc-9 flush @$50, EGR delete kit around $150,... it's not that difficult of a job to do, it just takes a little more time than other like jobs since the coolers are buried you have to remove a few extra components.
The bright side is getting to know your vehicle a lot better while addressing other mods you might want to do while you're in there... AND you will always have heaps of help from FTE members to walk you through any "unchartered territory" under the hood saving you over $100/hr shop time.
Thread Starter
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Junior User
Joined: Jan 2011
Posts: 73
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Well I talked to the fealer again. They confirmed the only thing that failed is the oil cooler. They said everything else needs to be replaced b/c in their "experience" when oil eta into all those parts they tend to fail in a couple weeks. So I know for certain I'm going to replace the oil cooler and put in an Egr delete, any preference on brands or just go with somethig decetly priced? After that ill hope the radiotor and hoses hold up for awhile. Any other sugestions on what I should take care of or upgrade while I'm there? The truck is pushing 200k miles.