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I have normal pressure in the cooling system. But when I test it with a gauge or the bubble test it will bubble at high rpm 3000-4000 rpm, and the pressure will build up the 16psi blow off point. Other than that it seems to run good. This has been an issue for 2 years, causing degas bottles to break and a radiator to leak. Any idea with the high rpm if it points to egr cooler or head gasket? Also it does the same thing with bubbles and pressure with or without turbo wire plugged in, but again only at high rpm.
idle temp is 180, was able to get it to 198 I believe, delta has never been above 16 and that was probably pulling a hill loaded, generally delta is 10 or so. Only reason I did the high rpm bubble test was out of frustration from not seeing any bubbles, yet having a leak in my year old mishimoto aluminum radiator. Degas bottle before that leaked, before that the plastic radiator. Something is causing it. I’ve switched degas caps multiple times. I don’t ever see those high pressures when driving normal.
Ford changed the EGR cooler in the middle of the '04 model year. If your '04 has the wavy oil rails (ICP on the passenger valve cover), then it has the weaker EGR cooler. Even so, clearly both designs have the potential to leak, just that the (early) "tube design" was a bit stronger.
Coolant level and concentration? Both can make a difference.
With the oil and coolant temperature differential being good, it doesn't seem that your EGR cooler was "starved" for coolant flow.
I put in a new radiator today. Did an oil cooler coolant system flush with air and water, refilled the system with 50/50 mix. Did all the same test I ran yesterday. No bubbles, no pressure spikes at any rpm. Did the same hard pulls I did yesterday to stress the system and the pressure never went above 4psi. Temps were about 5 degrees cooler and delta never went over 10 and was only about 4 cruising on the highway with no load. I guess I’m going to call it good, I’m concluding because of the leaks and subsequent refills that likely watered it down the coolant was boiling. Still don’t understand what caused the radiator that was a couple years old and supposed to be the one of the best on the market to leak. Hopefully just my bad luck.
Keep your degas level (cold) about 3/4 to 1/2 inch below the minimum line.
Just noticed that you did a flush with water and only filled back with 50/50. That means that the best you have is about a 30% concentration. There is a lot of volume in the system that doesn't drain out (about 2 gallons).
I blew out and drained out all I could, then put in 50/50 till it came out. I added about 5 gallons of coolant. I can test it, and drain a little and fill with concentrate if I need to. I have been debating for years if I want to keep this truck and delete and bulletproof it or get something else. I’ve always thought when a head gasket blows I’ll do it, I thought this was the time but it doesn’t seem so.
I blew out and drained out all I could, then put in 50/50 till it came out. I added about 5 gallons of coolant. I can test it, and drain a little and fill with concentrate if I need to. I have been debating for years if I want to keep this truck and delete and bulletproof it or get something else. I’ve always thought when a head gasket blows I’ll do it, I thought this was the time but it doesn’t seem so.
The full volume is 7 to 7-1/4 gallons. That is why you must add 3.5 gallons of CONCENTRATE, and then fill to a full level with distilled water.
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