2005 6.0, 125,000 miles.
Coolant (gold) running down and dripping off the driver's side back of the engine. About once every 10 seconds - all night long. One dealer replaced the degas bottle saying it had a hairline crack, however there was no sign of leaking behind or under the degas. No I did not ask to see the old part with the crack. (Stupid is hard to fix. Ask my wife!)

Friend mechanic, put pressure on the system and got steady leak from the same area but could not see the leak. He does not work on diesels. Says, that if dealer number 1 had pressurized the system, they would have found that they were not finished.

So I go to the next dealer (stupid is teachable), after it sat there for 4 days with no news, on AM day 5, service writer called to say it was a leak at the thermostat housing. I "trust" their diagnosis get the repair and bring it home. STILL dripping from the same spot as before. Is the thermostat housing on the front of the engine?

I've read all of the coolant leak posts but most seem to be about passenger side leaks. Mine is only on the driver side.

Any ideas? It is parked back at dealer #2, and I'd like to be able to talk somewhat intelligently concerning what they should look for.

If this is EGR related, should I skip the EGR repair and go ahead with the EGR removal?

Thanks for any help!

 

I'm going to assume that the truck is parked level when you notice this leak? If so, I'd look for the leak to be on the heater return hose that crosses behind the engine and returns below the degas bottle. Also, lay under truck and look at the rear of the block...below the exhaust manifold between #6 and #8 cylinders to see if the block plug is leaking. That's the only places I can think of that you'd have coolant coming without a cracked block or leaking head gasket.

 

Truck is usually parked on a slight downward angle, several inches lower at the front.

 

check the heater hose that runs next to the ficm.

 

If you open the hood and put you hand on the
top radiator hose it goes to the thermostat housing
on the engine
Do what Zhilton check that crossover with some pressure
in the system so you can see if that is the leak.
Also check the small hoses going to the degas
just to be sure.

Sean

 

Dropped off the truck at the dealer before starting this thread. Thanks for giving me some educated possibilities. I've paid for two repairs that did not stop my leak. I'm going to ask for proof that they have located the leak before approving another repair.

I'll let you know what solution is reached.

 

Dealer says it is leak at EGR and is recommending that I change out the oil cooler at the same time since they would have everything off making it easier.. Their repair estimate is approx $1500 for EGR repair + $700ish for the oil cooler work....

I'm thinking now is the time to do the EGR deleate myself.

While I "have everything off of the engine," should I do anything to the oil cooler?

 

Cheezit, whose EGR delete kit did you use?

 

The leak is on the driverside, yet the EGR cooler is on the passenger side. And it is leaking? Did they point to where the leak actually is?

Even when the EGR cooler hose is leaking, it tends to leak off the passenger side.

From down in here: (the EGR cooler has the numbers written on it)

 

this pretty well covers the correct awnser here. looks like you have a bad case of going to the dealer and saying "show me"

 

If...IF...the leak is really coming from the EGR cooler area of the engine, then yes you'd be time ahead to do the oil cooler now. Clay at RiffRaff can hook you up on one:

Riffraff Diesel: Ford Oil Cooler 03-07

To get to both the oil & EGR coolers, your going to have to pull the turbo. I'd get the "reconditioning kit" (4C4Z-9V424-AA). It comes with all the o-rings, gaskets and hardware for the turbo...it also comes with the 3M pads & high temp to clean the vanes on the exhaust side. The kit goes for about $60 through your Ford parts department.

But unless you've got the truck parked nose/passenger side high...I seriously doubt your EGR cooler/connector hose is the source of your coolant leak.

 

Has anybody seen an EGR cooler leak coolant onto the top of the engine except at the hose? Sure they leak internally all the time but dang, change the cooler cause the hose is leaking? Might as well do the oil cooler "while were in there" wow what *****!
Given the drip is on the drivers side I don't think it's even the hose but check the price on these p/n's posted by Bismic in an earlier post:

Coolant hose for egr cooler - 4C4Z-8592-AA
Inner O-ring for outlet port - 3C3Z-9N693-FA (International: 1846975C1)
Outer O-ring for outlet port - 3C3Z-9N693-EA (International: 1846977C1)

I believe the International part # for the hose is 1837845C2

My vote is on the Heater hose by the FICM mentioned above.

 

I have seen a few leak at the o-ring that goes into the intake. and maybe one or 2 devolp pinhols at the back of the tube were the blue hose goes but nither is common.

 

So (in Mythbusters speak) this is plausible? Woulda never though it.

 

i would have to agree with cheezit on the possible leak at the heater hose by the ficm. i've pulled out the ficm which is a PITA and i had to crouch low on my werner platform (and i'm about 6' 1") which doesnt help my posture and knees at all. there is a thick heater hose back there. could be tat. just saying.