Intercooler Flush
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Post Fiend
Joined: Feb 2007
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From: Dallas-Ft. Worth
Intercooler Flush
I picked up my 2002 F250 7.3L PSD in mid-January with 60k on it. I've already begun the mods, as some of you may have read. I've already done the CCV mod, but I haven't removed the rest of the components to clean them yet. I plan on cleaning the I/C tubes & boots and removing the wrapping on the hot-side tube, but how do you all flush the I/C itself short of removing it? I imagine that there is a fair amount of oil in it. Also, do the orange CAC tubes under the Y-pipe need to be replaced or can they be cleaned and reinstalled?
Sorry if this is old-hat, but I've been reading & perusing the forum for several weeks and haven't seen anything directly related to these issues yet.
Joe
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2002 7.3L F250 XLT CrewCab ShortBed 2WD
Sorry if this is old-hat, but I've been reading & perusing the forum for several weeks and haven't seen anything directly related to these issues yet.
Joe
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2002 7.3L F250 XLT CrewCab ShortBed 2WD
Post Fiend
Joined: Jun 2006
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From: Central, Al
To flush the intercooler it needs to be removed. All 6 of the boots can be cleaned and replace but the oil degrades them over time so a new boot set while not required is good to do. http://www.dieselsite.com/index.asp?...rodID=547&HS=1
Lead Driver
Joined: Oct 2004
Posts: 7,413
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From: Columbia, MO
There's just no good way to flush it without removing it. Alan is correct, as usual. 
When you flush the IC, it needs to be able to stand on one end to let all of the water drain out. And, I'm not sure you could get all parts of it clean unless you were able to lay it flat.
Removal of the IC is not all that difficult though. It would take maybe 1-2 horus for a first timer.
When you flush the IC, it needs to be able to stand on one end to let all of the water drain out. And, I'm not sure you could get all parts of it clean unless you were able to lay it flat.Removal of the IC is not all that difficult though. It would take maybe 1-2 horus for a first timer.
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Post Fiend
Joined: Feb 2007
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From: Dallas-Ft. Worth
Thanks fellas -- I'll get on it one of these weekends. I'm a little green on the SuperDuty, but I've done my fair share of wrenching on my other vehicles, plus I've been around diesels in the military for years... 
I just wasn't looking forward to yanking the radiator & fan, plus draining the cooling system that was just serviced at the dealer when I bought it. They replaced the thermostat & temp sensor because the temp guage wasn't reading on my test drives. I know I can just capture all the coolant and dump it back in but I just hoping there might be a simpler way.
What do you guys use to flush it? Some kind of mineral spirits or something?
Joe
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2002 7.3L F250 XLT CrewCab ShortBed 2WD
I just wasn't looking forward to yanking the radiator & fan, plus draining the cooling system that was just serviced at the dealer when I bought it. They replaced the thermostat & temp sensor because the temp guage wasn't reading on my test drives. I know I can just capture all the coolant and dump it back in but I just hoping there might be a simpler way.
What do you guys use to flush it? Some kind of mineral spirits or something?
Joe
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2002 7.3L F250 XLT CrewCab ShortBed 2WD
Post Fiend
Joined: Jul 2005
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From: 21791
You don't need to do any of that. Remove the rubber tray clips that is between the grille and the crossmember, 4 bolts on each side of the crossmember, and then the crossmember pops out. The IC is right below that, and then that is all you need to remove it. No draining the radiator, fan removal etc.
Locomotive breath
Joined: Jan 2006
Posts: 1,354
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From: Mid Oh. Ponderosa
Hey guys, this is just one more item on my to-do list, but how would you be sure of getting all the water out, or other de-greaser or solvent? Certainly would not want the engine to ingest.
Thanks, Bill
Thanks, Bill
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Post Fiend
Joined: Feb 2007
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From: Dallas-Ft. Worth
Originally Posted by strokin_it7.3
You don't need to do any of that. Remove the rubber tray clips that is between the grille and the crossmember, 4 bolts on each side of the crossmember, and then the crossmember pops out. The IC is right below that, and then that is all you need to remove it. No draining the radiator, fan removal etc.
Joe
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2002 7.3L F250 XLT CrewCab ShortBed 2WD
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Cargo Master
Joined: Jan 2005
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From: Pasadena, Maryland
At 290k I had less than half a teaspoon of oil in the intercooler. It may be dirty but it wont be full of oil. I used simple green and flushed with hot water.
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Post Fiend
Joined: Feb 2007
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From: Dallas-Ft. Worth
Originally Posted by jetdoc
At 290k I had less than half a teaspoon of oil in the intercooler. It may be dirty but it wont be full of oil. I used simple green and flushed with hot water.
Thanks for the info.
Joe
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2002 7.3L F250 XLT CrewCab ShortBed 2WD
Locomotive breath
Joined: Jan 2006
Posts: 1,354
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From: Mid Oh. Ponderosa
Originally Posted by jetdoc
At 290k I had less than half a teaspoon of oil in the intercooler. It may be dirty but it wont be full of oil. I used simple green and flushed with hot water.
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Post Fiend
Joined: Feb 2007
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From: Dallas-Ft. Worth
Originally Posted by DISLFVR
If that's all, why bother.
Joe
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2002 7.3L F250 XLT CrewCab ShortBed 2WD
Post Fiend
Joined: Jul 2005
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From: 21791
Originally Posted by DISLFVR
If that's all, why bother.
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Post Fiend
Joined: Feb 2007
Posts: 14,541
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From: Dallas-Ft. Worth
True...True...
I just want to know my intake is squeaky clean. That way, when I put my exhaust & chip in, I know it's breathing as best it can...
Joe
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2002 7.3L F250 XLT CrewCab ShortBed 2WD
I just want to know my intake is squeaky clean. That way, when I put my exhaust & chip in, I know it's breathing as best it can...
Joe
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2002 7.3L F250 XLT CrewCab ShortBed 2WD
Locomotive breath
Joined: Jan 2006
Posts: 1,354
Likes: 1
From: Mid Oh. Ponderosa
Originally Posted by strokin_it7.3
Some of us that are PMS-infected have the urge to tinker with our trucks, even if there is really no benefit to doing it. It's just something to do to ease the PMS urge.
Now back to my first question about how to make sure all water or solvent is out of i/c ?