I'm getting ready to have to do this as well on my 2002. I'm loosing about a gallon of oil every 3-4 weeks, and it looks to me like it's all coming from the gasket on the back end of the cooler. Also, the gasket is bad enough to where I'm getting a little pressurized spray on the back side of the engine block and the entire underside of my driver side is coated with oil. I'm not seeing any evidence yet of oil in my coolant or loss of coolant, so I believe it's really just the gasket only which has failed, but I'm going to do the o-rings proactively.

BTW... the cooler rebuild kit I got from my local dealer this past weekend was about $60 (both small o-rings, both large o-rings, and the rear gasket... don;t remember seeing the front gasket, but I'll get it if it's not already there).

EDIT... I had some questions, but then found Robin's posts in another thread of the same topic, so I'm good. Here is a link to the other thread.
https://www.ford-trucks.com/forums/1...life-span.html

 

Be sure to use plenty of lubricant on the O-Rings. If you can get some grease specifically designed for O-Rings. It will make the tube bundle slide into the heads easier. Mark the relative position of the bundle to the heads so when you reassemble it things will line up. I used a press to insert the bundle because it was difficult to insert by hand.

 

Thanks. In my spare time, I represent an industrial lubricant company, so I have access to some excellent options lubing the o-rings. Since my post above, I've read through several versions of the resealing procedure from a variety of threads, and will be compiling everything I can find on "best practices" and "options" into a single document which will also contain links to all the helpful threads I've found. This way, we can all have a single source for FTE's intelligence in one document, and I'll post it up once I've finished the job myself.

 

Subscribing. Thanks Pete. I will look forward to it.
I haven't had to do mine, yet. I know it's time is coming.

 

X2, Mine leaked one really cold day this past winter. I plan to do this sometime this summer?

 

I also discovered that the $60 I spent at the dealer was just for the o-rings. I'm returning the kit to the dealer and have already ordered a COMPLETE kit from Bob at Diesel Orings. I'm just going to have to suffer through pumping oil to the ground for the next couple of weeks until I can get some time off after my extended shutdown coverage of 7-12's for 12-14 days, but that leaves plenty of time for Bob's kit to arrive.

 

Shoot me a PM when you get it done and I'll add it to the FAQ.

 

I'm in the same boat, with mine leaking a few times last winter. I got the kit and the oil and filter, just need to get the coolant and the time.

 

Thank you both.

Been seeing you around a little Scott.

 

Will do, Scott.

 

Good to see ya' Rick! Glad you're still around

 

Just bought the o-rings and gaskets yesterday at an international truck dealer, cost me less than 70 bucks with the tax's. I can get the part numbers if you want them. I did the oil cooler on the 2000 X last weekend while I had the water pump off for replacement. It's not a bad job just kinda messy when the cooler comes off, you get a antifreeze/oil bath for about 2 seconds. I am going to run the truck a bit before I change oil. I put the filter back on and just added some oil.

 

I wouldn't run the truck before change oil after a cooler fix! Lots of coolant ran down into the filter and pan when you removed the cooler and if you run the truck now just a tablespoon of that coolant could ruin you day!