Was rotating the tires Tuesday and noticed the dreaded bell housing leak with one drop hanging and the bellhousing wet. Took it to the dealer Wednesday morning and dropped it off. Got a call at 5pm same day and the sa said that the truck was ready. They replaced the top cac hose at the turbo since it was weeping and replaced the crankshaft position sensor o-ring. Sa said the o-ring leak at the front of the motor was traveling down crevices alongside the motor to the rear and down the bell housing. Good find in my opinion and got the truck back the same day. Kudos to the dealer. Hemborg Ford in Norco, ca.

 

MMMMM. Yeah, I was told the same thing on my '03 and the leaks just got worse every time they played with something. The last straw was when the truck was in the shop for 6 weeks with a bedplate re-seal. The day it came back to me was the day I dropped it off up front for a trade in. I hope all works out for you with that and they got it. The reason I am so skeptical on the leak problem is that my '06 has the same exact bell housing leak as the '03. Ford was well aware of these leaks as far back as '03 and they were still not corrected from the factory in '06. Unless it's puddling under my truck, aint nobody touching it this time. Anyway, Good luck, just keep your eye on it.

 

that is my opinion too, if there is not a noticile spot were it drips every night, the dealer is not touching it

 

Do not ever let the dealer fix an oil leak on these 6.0 diesels without first running a dye test. Dye is added to the oil and the owner is told to drive the truck for 500 miles. The truck is then returned to the shop and a black light is used to find the source of the leak. There are 15 ( or so ) leak sources that can show up as a drip on the bell housing. Without the dye test, the mechanic is simply guessing.

 

HERE IS A COMPILATION OF THINGS FOUND ON OIL LEAKS (and why you MUST get a dye test):

Generally almost all oilleaks end up running onto the rear of the motor, bell housing and transmission.


Possible Sources:
<O
Weeping return hose from the intercooler that was putting a little oil up on top of the engine that found it's way down the back and to the bell housing.
<O</O<O</O

CAC Tubes:
The CAC tube oil leak is caused because the crankcase ventilation is routed into the inlet side of the turbo, and oil build up in the tubes is normal, and then it seeps out around the hoses and onto the top of the engine then runs down the rear of the engine onto the bell housing.
<O</O

Check to see if you have an icp sensor in your right valve cover (03 and early 04). if you don’t, then it is under your turbo. The icp sensors have caused many oil leak concerns, especially on the 03 to early 04.

Oil Leaks from Lower Engine Area:
Some 6.0 engine may exhibit an oil leak that appears to be coming from the lower crankcase (bedplate), upper or lower oil pan, rear main seal, or front or rear covers. First inspect the cam and crank position sensors to ensure the leak is not the o-ring on one of these sensors. If the sensor(s) is wet, remove it and replace the o-rings. Cam sensor (driver side) 3C3Z-9N693-HA and JA. Crank sensor (passenger side) 3C3Z-9C064-DA.
An oil leak may occur at front or rear covers if they were removed without cutting the sealing joints behind them. Broadcast Message 1268

Oil Leaks from Front and/or Rear Crank Seals:
If an oil leak has been verified as coming from either the front or rear crankshaft seals, the crankshaft end play must be checked to ensure it is 0.020 inch or less. If within specs, replace the seal using the correct tools and procedures. Broadcast Message 1240
<?xml:namespace prefix = st1 ns = "urn:schemas-microsoft-com[img] /><st1:NumConv6p0 val=[/img][font=Verdana>04</FONT></FONT></st1:NumConv6p0><FONT][/font]<st1:NumConv6p0 val=" /><st1:NumConv6p0 val="1240" sch="1"></st1:NumConv6p0><O</O
<st1:NumConv6p0 val="2003" sch="1"></st1:NumConv6p0>
<st1:NumConv6p0 val="2003" sch="1"></st1:NumConv6p0>
<st1:NumConv6p0 val="2003" sch="1">2003</st1:NumConv6p0>-<st1:NumConv6p0 val="2004" sch="1">2004</st1:NumConv6p0> Oil Leak from Head Gasket:
Some engine may exhibit what appears to be an oil leak from the head gasket. Since there is no pressurized oil at the head gasket, a leak at this location is unlikely. Inspect the following area instead: turbo oil feed and return, oil cooler, HP oil pump cover, ICP sensor, IPR valve, valve cover gasket, rocket carrier gasket, Injector and glow plug ports and crankcase breather port. Use florescent dye and an UV lamp to pinpoint the source of the leak. If the leak is from the head gasket, the head should be removed and it and the block checked for flatness. Broadcast Message <st1:NumConv6p0 val="0873" sch="1">0873.</st1:NumConv6p0>
<st1:NumConv6p0 val="0873" sch="1"></st1:NumConv6p0>
<O</O

Rear Main Seal Leak:
Some trucks with the <st1:NumConv6p6 val="6.0" sch="4">6.0</st1:NumConv6p6> may exhibit what looks like an oil leak from the bellhousing, presumably for the rear main seal. This actually may be excessive grease from the torque converter pilot melting and running out of the bellhousing. It is recommended that <st1:NumConv6p0 val="3" sch="1">3</st1:NumConv6p0> ounces of florescent dye be added to the oil, the truck driven, then the leak inspected with an UV lamp. If dye is detected, the engine should be inspected for leaks on top that may be running down the back of the engine. If no upper leaks are detected, replace the rear main seal. Broadcast Message <st1:NumConv6p0 val="1017" sch="1">1017.</st1:NumConv6p0>
<st1:NumConv6p0 val="1017" sch="1"></st1:NumConv6p0>
Oil supply line to the turbo.

Bedplate gasket - sealing surface for the bed plate on the cylinder block assembly

<O</O
Oil Pan/Bed Plate:<O</O

· The <st1:NumConv6p6 val="6.0" sch="4">6.0</st1:NumConv6p6>L Power Stroke uses a two piece oil pan. The lower half is wider than the bottom of the engine to increase its capacity. Due to this wider oil pan, an upper oil pan is used to adapt the lower pan to the bed plate. The upper pan also acts as an oil baffle.

· The upper pan is bolted to the bed plate. The bed plate replaces the individual main bearing caps. This one piece design results in a more rigid bearing retaining system.

The pick-up tube is bolted to the upper pan and oil is routed through the upper pan and the bed plate to the front cover.<O</O<O</O

The most common leaks on the <st1:NumConv6p6 val="6.0" sch="4">6.0</st1:NumConv6p6> are as follows in descending order of occurrence: (Notice the First for items comprise <st1:NumConv6p0 val="65" sch="1">65</st1:NumConv6p0>% of all reported leaks and are a simple fix.) from Blackhat<st1:NumConv6p0 val="620" sch="1">620</st1:NumConv6p0>

CAC Tubes = <st1:NumConv6p0 val="21" sch="1">21</st1:NumConv6p0>%
ICP Sensor = <st1:NumConv6p0 val="16" sch="1">16</st1:NumConv6p0>%
Glow Plug Harness = <st1:NumConv6p0 val="14" sch="1">14</st1:NumConv6p0>%
Cam/Crank Position Sensor =<st1:NumConv6p0 val="14" sch="1">14</st1:NumConv6p0>%
Front Crankshaft Seal = <st1:NumConv6p0 val="8" sch="1">8</st1:NumConv6p0>%
Upper to lower block seal (skirt) = <st1:NumConv6p0 val="5" sch="1">5</st1:NumConv6p0>%
HPOP cover = <st1:NumConv6p0 val="4" sch="1">4</st1:NumConv6p0>%
Oil Cooler (this leaks into engine coolant) = <st1:NumConv6p0 val="4" sch="1">4</st1:NumConv6p0>%
Front or Rear Engine Cover = <st1:NumConv6p0 val="3" sch="1">3</st1:NumConv6p0>%
Rear Crank Seal = <st1:NumConv6p0 val="3" sch="1">3</st1:NumConv6p0>%
Turbo Charger & VGT actuator = <st1:NumConv6p0 val="2" sch="1">2</st1:NumConv6p0>%
Covers (oil pan, valve covers, breather) = <st1:NumConv6p0 val="2" sch="1">2</st1:NumConv6p0>%
Cracked or Porous Block or Head = <st1:NumConv6p0 val="1" sch="1">1</st1:NumConv6p0>%
IPR valve/Engine Lube oil pump = less than 1%<O</O