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6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

Leaking coolant again :(

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Old Dec 14, 2024 | 09:40 AM
  #106  
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So would it be an issue if I drained my coolant till I can get the O ring replaced just so I don't keep leaking coolant all over the ground?
 
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Old Dec 14, 2024 | 10:22 AM
  #107  
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I would drain about a gallon and see how that goes. The problem you have with draining all the coolant out of the engine block is the potential for the cooling jacket to develop rust. And that makes for an unhappy oil cooler.
 
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Old Dec 14, 2024 | 10:52 AM
  #108  
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Originally Posted by TooManyToys.
I would drain about a gallon and see how that goes. The problem you have with draining all the coolant out of the engine block is the potential for the cooling jacket to develop rust. And that makes for an unhappy oil cooler.
Looks like it's already leaked a gallon so I'll check to see if it's still leaking.
 
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Old Dec 15, 2024 | 08:54 AM
  #109  
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Well I'm tired of not being able to use the truck and it's fairly nice out today so I'm going to rip into the engine again and get as far as I can get and finish it another day if need be. Looking at older pics I noticed that my intake manifold has the tab in place still so I guess that means the turbo has to come out and if so whatever lol.

I'll also have to disconnect the Fuelab regulator and move the fuel lines out of the way and hopefully it won't be a constant stream of diesel and is just whatever is in the lines that comes out. Once I get everything out of the way of the manifold I'm going to vacuum the top of the engine then spray with brake kleen then blow it off with air very thoroughly and get started on loosening the manifold bolts and replacing that stupid O ring!

Should I be rubbing some clean oil on the new O ring before putting it in place or just wipe everything down good and install dry?

Thanks fellas and wish me luck here lol



 
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Old Dec 15, 2024 | 10:07 AM
  #110  
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You can get one of these small handheld hacksaw’s at most hardware stores or big box stores for about $10-$20 US. That would allow you to cut off the soft aluminum tab on the intake so you don’t have to pull the turbo.

And do not use oil on a coolant ring.








 
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Old Dec 15, 2024 | 11:10 AM
  #111  
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Originally Posted by TooManyToys.
You can get one of these small handheld hacksaw’s at most hardware stores or big box stores for about $10-$20 US. That would allow you to cut off the soft aluminum tap on the intake so you don’t have to pull the turbo.

And do not use oil on a coolant ring.


Awesome, thanks TTT 👍
 
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Old Dec 15, 2024 | 12:53 PM
  #112  
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Originally Posted by TooManyToys.
You can get one of these small handheld hacksaw’s at most hardware stores or big box stores for about $10-$20 US. That would allow you to cut off the soft aluminum tab on the intake so you don’t have to pull the turbo.

And do not use oil on a coolant ring.
Looks like i don't have to worry about that tab after all.




Here's where I'm at right now:







The passenger side manifold bolts will be easy, but the bolts on the drivers side will be a bit of a pain so will the rtv I put on last week to try and stop the leak. I'll scrape as much off as possible and hopefully I don't get any pieces into the coolant when swapping out the O ring.

Also my air compressor is kaput for some reason so crossing my fingers and saying a prayer that i don't get any crud into the intake ports when I lift up the manifold. I'll just try my best to not move the manifold around and cross my fingers.

 
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Old Dec 15, 2024 | 02:59 PM
  #113  
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I had to remove the degas bottle and FICM to get at the drivers side bolts, but manifold is up now and will replace the O ring then start putting everything back together.







 
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Old Dec 15, 2024 | 03:57 PM
  #114  
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Old one out:




New one in:



Now to torque the manifold in sequence and to 8 foot pounds then put everything back together tomorrow hopefully.

What a battle this has been 😵‍💫
 
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Old Dec 16, 2024 | 04:04 PM
  #115  
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Well I got everything put back together now and no leaking even when getting up to temp so crossing my fingers everything is good now, but won't know for sure till the engine cools down and outside temp goes back to -15c or lower. HOPEFULLY no more issue till summer at least lol

 
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Old Dec 17, 2024 | 07:34 AM
  #116  
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Truck has been sitting in -10c temps overnight and no coolant under the truck so looks like the O ring swap was a success

Thanks again fellas.
 
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Old Jan 26, 2025 | 07:52 PM
  #117  
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Took the truck for a short drive yesterday(haven't driven it since the O ring replacement)and I noticed a very out of place low tone whistle so I checked/adjusted all the CAC tubes/boots and everything is as it should be and went for another drive and the whistle is still there. It starts around 60kph when giving it good throttle and goes away when I Iet off or when cruising so I'll have to investigate further and crossing my fingers it's not the intake manifold not being seated properly cause that would really suck!

Boost/power is there, no codes and runs/drives just fine so I dunno
 
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Old Jan 26, 2025 | 07:55 PM
  #118  
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Did you do an exceptional job of cleaning dirt from around the intake to head connections before lifting the intake?
 
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Old Jan 26, 2025 | 08:56 PM
  #119  
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Originally Posted by TooManyToys.
Did you do an exceptional job of cleaning dirt from around the intake to head connections before lifting the intake?
Not exceptional, but blew it out with air for a solid 20 minutes. Having to remove the whole top of the engine and intake manifold to get at that O ring is such a BS design 😖😠
 
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Old Jan 27, 2025 | 07:00 AM
  #120  
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Not sure why you had to, I didn't.
 
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