Just had some work done on my truck due to coolant puking. Covered on warranty but the invoice comments including reference to some TSB's that the mechanic followed. FTX helped me with one but I need to know if anyone has access to the other two. They are:

TSB 08-16-13 and TSB 08-11-3.

Thanks.

 

One suggestion, get the service manager at your dealer to print them out for you. If you get them please let us know because you have me curious about them also.

 

08-16-13 Aug 08 6.0L TURBOCHARGER CARBON DEPOSIT DIAGNOSTICS AND SERVICE TIPS

<TABLE border=0><TBODY><TR><TD width=230>FORD:
</TD><TD>2003-2005 Excursion
2003-2007 F-Super Duty
2004-2008 E-350, E-450</TD></TR></TBODY></TABLE>


This article supersedes TSB 08-4-7 to update the Service Procedure. ISSUE:


Some 2003-2007 F-Super Duty, 2003-2005 Excursions, and 2004-2008 E-350/450 vehicles equipped with a 6.0L diesel engine may exhibit any one, or a combination, of the following concerns: lack of power, white/black smoke or a surge. These concerns may or may not be accompanied by any one, or a combination, of the following diagnostic trouble codes (DTCs): P0238, P0299, P0404, P0478, P2262 and/or P2263. These concerns and/or DTCs could be a result of coking deposits inside the turbocharger.
ACTION:

Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE



Coking deposits inside the turbocharger turbine housing can impede vane response causing high or low instances of exhaust pressure. Unexpected exhaust pressure results can cause over-boost, under-boost, insufficient or excessive exhaust gas recirculation, or unexpected EGR valve position, resulting in these symptoms.
This TSB is for diagnosis and cleaning of the variable geometry turbocharger (VGT) vane set and the center housing and rotating assembly (CHRA), and for replacement of a corroded CHRA.
For F-Super Duty, Excursions, and E-Series vehicles built on or before 9/29/2003, follow pin point test KA in the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostics. If the pin-point test in the PC/ED manual diagnostics leads to turbocharger replacement, use this Turbocharger Inspection Procedure first to check for internal turbocharger oil leaks, and to determine if the turbocharger can be repaired with a CHRA replacement, or if it can be cleaned, instead of replacing the entire turbocharger. (Figure 1)


Figure 1 - Article 08-16-13


For F-Super Duty, Excursions, and E-Series vehicles built on or after 9/30/2003, install the VPS tool 418-626 along with IDS/VMM. The 418-626 was shipped in kit TKIT-2007VP-F and TKIT-2007TV-F. Dealers should have received one or the other of these two kits. To Install VPS

1. Remove the threaded pipe plug from center housing of turbo.
2. Remove the oil supply flange bolt closest to the turbo label.
3. Drop in the VPS and secure with provided clamp flat side up.
4. Torque the oil supply line bolt 7 lb-ft (10 N-m).
5. The gasket is reusable and need only be replaced if an oil leak is present after final assembly.
   To run test, start new session in IDS with VPS/VMM connected to the vehicle. Then select the Toolbox-Powertrain-Air Management-Boost test and follow the IDS screen prompts, and then continue with VVT test. Both the boost and VVT test should be run in order.
   Once each of the tests are complete, use the IDS help icon on the right side of the screen in each test to help analyze the results. If the turbo fails and leads to turbocharger replacement, continue with the Turbocharging Inspection Procedure to check for internal turbocharger oil leakage and to determine if the turbocharger can be repaired with a CHRA replacement, or if it can be cleaned, instead of replacing the entire turbocharger.
   If the turbocharger passes the turbo tests, do not continue with this TSB. Follow the online KA pin point test found on the Professional Technician Society (PTS) website and continue air management diagnosis without replacing the turbocharger.
   <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>VEHICLE PERFORMANCE ISSUES RELATED TO FUEL QUALITY, MAINTENANCE AND AFTERMARKET MODIFICATIONS ARE NOT COVERED BY FORD MOTOR COMPANY WARRANTY.</TD></TR></TBODY></TABLE>

Turbocharger Inspection Procedure

1. Remove the turbocharger for inspection following Workshop Manual, Section 303-04D: Fuel Charging and Controls.
2. Inspect compressor and turbine wheel fins for damage. Replace the turbocharger if fins are damaged. If fins are damaged, inspect the air intake system for damage allowing dirt or contamination to bypass the air filter.
3. Perform a turbocharger bearing clearance check following Workshop Manual, Section 303-04D. Replace turbocharger if bearing fails the check.
4. Cover the inlet and outlet of the turbocharger compressor housing with duct tape or covers. Clean the oil supply line mounting surface and cover with duct tape or covers. Place a clean paper towel or cover into the turbocharger oil drain passage.
5. Using a paint pen, mark the location and direction of the v-clamp (Figure 2).
   
   
   Figure 2 - Article 08-16-13
6. Using a paint pen, mark the location of the turbine housing at unison ring crank to make reassembly easier (Figure 3).
   
   
   Figure 3 - Article 08-16-13
   
   
   <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>DO NOT REMOVE COMPRESSOR HOUSING AT THIS TIME, OR TURBINE WHEEL/COMPRESSOR WHEEL ASSEMBLY.</TD></TR></TBODY></TABLE>
7. Remove the v-clamp retaining nut completely from clamp assembly. Move v-clamp from flanges so the turbocharger housings can be separated (Figure 4).
   
   
   Figure 4 - Article 08-16-13
8. Separate the housings using a hammer and brass drift.
9. Separate vanes and unison ring from turbine housing and center housing and check for coking from oil. If turbocharger is coked with carbon deposits from oil, the deposits will be wet and black and cover the complete inside of the turbo (Figure 5).
   
   
   Figure 5 - Article 08-16-13
   1. Inspect the unison ring for cracks. Replace the turbocharger if the unison ring is cracked.
   2. If the turbocharger is oil coked, go to the Turbo Cleaning Procedure, below.
   3. If the turbocharger is not oil coked, and/or if corrosion is present on the bearing housing flange, use the CHRA Replacement Procedure, below, and the Turbine Housing and Vane Set Cleaning procedure.
      <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>DO NOT ATTEMPT TO CLEAN RUST OR CORROSION, OR PITTING FROM THE CENTER HOUSING FLANGE OR HUB. (Figure 6)</TD></TR></TBODY></TABLE>
      
      
      
      Figure 6 - Article 08-16-13
      
      
      <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>SCALY RUST, CORROSION OR PITTING MAY BE PRESENT INSIDE THE TURBINE HOUSING. THIS IS NORMAL. DO NOT TO REPLACE THE TURBINE HOUSING. VANE SET CLEANING WILL BE SUFFICIANT</TD></TR></TBODY></TABLE>
      
      <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>TRANSFER THE VGT SOLENOID FROM THE TURBOCHARGER OR CHRA BEING REPLACED.</TD></TR></TBODY></TABLE>

CHRA Replacement Procedure

1. Temporarily set the CHRA with attached compressor housing onto the turbine housing, compressor side up, for the following steps.
2. For 2003 model year vehicles only: Examine compressor housing attachment to CHRA. If the six (6) compressor housing screws thread into separate clamp plates, then the turbocharger is of early 2003 vintage. In this case, place a mark on the compressor housing directly in line with the mark previously placed on the turbine housing. If the six (6) screws thread directly into the CHRA, it is a later version, and there is no need to align-mark the compressor housing. This change is not associated with a specific VIN number, but the correct configuration CHRA kit must be ordered. (Figure 7)
   
   
   Figure 7 - Article 08-16-13
3. Remove the six (6) compressor housing screws.
4. Tap the compressor housing loose with a mallet, and remove it from the CHRA. Take care to not damage the old compressor wheel fins.
5. Carefully set aside the old CHRA core.
6. Temporarily set the new CHRA onto the turbine housing, and install a new rubber seal ring to the CHRA flange. (Figure 8)
   
   
   Figure 8 - Article 08-16-13
7. Align and install the compressor housing onto the new CHRA. The compressor housing can only be assembled one way for late model turbochargers. For the early 2003 turbocharger only, the mark on the compressor housing will need to be aligned with the mark on the turbine housing. Take care to not damage the new compressor wheel fins. Tap the compressor housing flange down with a mallet as needed to fully seat it.
8. Install the six (6) compressor housing screws and torque to 200 lb-in (23 N-m).
9. Go to the Vane Cleaning sub-procedure (in Turbocharger Cleaning Procedure, below).

Turbocharger Cleaning Procedure



<TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>A RAZOR BLADE IN A HOLDER MAY BE USED WHERE THERE IS SUFFICIENT ACCESS TO REMOVE THE BULK OF CARBON DEPOSITS. </TD></TR></TBODY></TABLE>

<TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>USE A DUST MASK WHEN CLEANING TURBOCHARGER SURFACES.</TD></TR></TBODY></TABLE>

1. Wet the areas to be cleaned (unison ring, vanes, vane contact areas on the turbine housing, and unison ring contact area on the center housing) with Motorcraft® Carburetor Tune-Up Cleaner. (Figure 9)
   
   
   Figure 9 - Article 08-16-13
   
   
   CHRA Cleaning
   <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>DO NOT CLEAN THE TURBINE WHEEL AND USE CAUTION WHEN CLEANING AROUND IT.</TD></TR></TBODY></TABLE>
2. After scraping, finish cleaning the center housing with a Scotch-Brite™ 2" (5 cm) abrasive disc 051131-07480, or equivalent (obtain locally). Ensure these areas are free of carbon: (Figure 9)
   • Center housing unison ring hub.
   • Center housing facing surface.
   Turbine Housing And Vane Set Cleaning
3. Clean the unison ring and vanes with a Scotch-Brite™ 2" (5 cm) abrasive disc 051131-07480, or equivalent (obtain locally). Ensure these areas are free of carbon: (Figure 12)
   • Unison ring - all surfaces.
   • Vanes - all contact points.
   <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>THE DISC MUST BE MODIFIED TO THE 1" (2.5 cm) SIZE TO COMPLETE THE CLEANING EFFECTIVELY.</TD></TR></TBODY></TABLE>
   
   <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>AVOID DAMAGING VANE PIVOT PINS DURING THE CLEANING PROCESS. PIN DAMAGE CAN CAUSE UNWANTED NOISE AND/OR IMPAIR TURBOCHARGER PERFORMANCE. (FIGURE 9)</TD></TR></TBODY></TABLE>
4. Using scissors, cut the Scotch-Brite™ disc used in step 12 to match a 1" (2.5 cm) 3M™ ROLOC™+ Holder (61-5000-7982-9). (Figures 10 and 11)
   
   
   Figure 10 - Article 08-16-13
   
   
   
   
   Figure 11 - Article 08-16-13
5. Finish cleaning the turbine housing using the modified disc. Remove the carbon deposits from all surfaces that contact moving parts, as well as the mating surfaces of the housing. (Figure 9 and 12)
   
   
   Figure 12 - Article 08-16-13
6. Apply a thin layer of engine oil to the turbine housing, center housing and unison ring. This procedure is to temporarily protect against surface corrosion. Applying anti-seize is not recommended.
7. Continue on to the Turbocharger Assembly Procedure.

Turbocharger Assembly Procedure

1. Install the vanes into the turbine housing:
   1. Index the unison ring onto the vanes.
   2. Align the crank pin slot with the paint pen mark on the turbine housing. (Figure 3 and 8)
   3. Verify free movement of the vanes and unison ring.
2. Position v-clamp on the turbine housing in direction of paint pen mark.
3. Lower the center housing section onto the turbine housing, aligning the unison ring crank first, then the housing dowel.
4. Align the v-clamp with the paint marks. Coat the threads with Motorcraft® High Temperature Nickel Anti Seize.
5. Install the locknut using steps a through d:
   1. Torque to 13 lb-ft/160 lb-in (18 N-m).
   2. Loosen nut and torque to 4 lb-ft/50 lb-in (5 N-m).
   3. Stand turbocharger on exhaust outlet. For early 2003 turbocharger only, verify correct alignment of compressor housing to turbine housing. Now tap around the aluminum compressor housing with a rubber mallet to ensure complete seating.
   4. Torque to 12 lb-ft/150 lb-in (17 N-m).
6. Remove the duct tape or covers from the turbocharger. Remove any tape residue with a paper towel dampened with Motorcraft® Metal Brake Parts Cleaner.
   <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>VGT SOLENOID REPLACEMENT IS NO LONGER NECESSARY. THE NEW OIL DRAIN TUBE WILL RESOLVE THE COKING ISSUE.</TD></TR></TBODY></TABLE>
7. Anytime the turbocharger is removed and prior to installation, check the drain tube. Identify the tube by its end configuration, the new larger tube has a wide inner shoulder and a tube OD larger than the o-ring groove bottom, If an earlier design tube is present, replace it. (Figure 13)
   
   
   Figure 13 - Article 08-16-13
8. Install the turbocharger with the correct oil drain tube following WSM, Section 303-04D: Fuel Charging and Controls.

<TABLE cellSpacing=0 cellPadding=3 border=1><TBODY><TR><TH align=middle>PART NUMBER</TH><TH align=middle>PART NAME</TH></TR><TR><TD class=NOBOTTOMBORDER align=left>6C3Z-9T515-A</TD><TD class=NOBOTTOMBORDER align=left>Oil Drain Tube</TD></TR><TR><TD class=NOBORDER align=left>W302676</TD><TD class=NOBORDER align=left>V-Band Clamp</TD></TR><TR><TD class=NOBORDER align=left>W302677</TD><TD class=NOBORDER align=left>Locknut</TD></TR><TR><TD class=NOBORDER align=left>PM-2</TD><TD class=NOBORDER align=left>Motorcraft® Carburetor Tune-up Cleaner</TD></TR><TR><TD class=NOBORDER align=left>PM-4A</TD><TD class=NOBORDER align=left>Motorcraft® Metal Brake Parts Cleaner</TD></TR><TR><TD class=NOBORDER align=left>XL-2</TD><TD class=NOBORDER align=left>Motorcraft® High Temperature Nickel Anti Seize</TD></TR></TBODY></TABLE>

<TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>THE FOLLOWING PARTS MUST BE ORDERED THROUGH THE LOCAL FORD AUTHORIZED DISTRIBUTOR (FAD).</TD></TR></TBODY></TABLE>

<TABLE cellSpacing=0 cellPadding=3 border=1><TBODY><TR><TH align=middle>PART NUMBER</TH><TH align=middle>PART NAME</TH></TR><TR><TD class=NOBOTTOMBORDER align=left></TD><TD class=NOBOTTOMBORDER align=left></TD></TR><TR><TD class=NOBORDER align=left>3C3Z-9G489-AARM</TD><TD class=NOBORDER align=left>Center Housing (Clamp Plate) - 2003 F-Super Duty/Excursion</TD></TR><TR><TD class=NOBORDER align=left>3C3Z-9G489-BARM</TD><TD class=NOBORDER align=left>Center Housing - (Bolted w/o Clamp Plate) 2003 F-Super Duty/Excursion</TD></TR><TR><TD class=NOBORDER align=left>4C3Z-9G489-AARM</TD><TD class=NOBORDER align=left>Center Housing - 2004-2005 F-Super Duty (Built before 11/4/2004), E-350/450, And Excursion (Built before 1/10/2005)</TD></TR><TR><TD class=NOBORDER align=left>5C3Z-9G489-AARM</TD><TD class=NOBORDER align=left>Center Housing - 2005 Excursion (Built after 1/10/2005), 2005-2007 F-Super Duty (Built after 11/4/2004) And 2005-2008 E-350/450</TD></TR></TBODY></TABLE>
WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
<TABLE cellSpacing=0 cellPadding=3 border=1><TBODY><TR><TH align=middle>OPERATION</TH><TH align=middle>DESCRIPTION</TH><TH align=middle>TIME</TH></TR><TR><TD class=NOBOTTOMBORDER align=left>081613A</TD><TD class=NOBOTTOMBORDER align=left>2003-2004 Super Duty, 2003-2004 Excursion 6.0L Built Before 9/29/2003: Follow Pin Point Test KA In The PC/ED Manual. If It Leads To Turbocharger Replacement, Follow Service Procedure To Determine Turbocharger Repair, Turbo Damaged, Replace Turbocharger, Includes Time To Remove Turbo For Inspection, Transfer The VGT Control To The New Turbocharger And Install (Do Not Use With 6089A, 9438A Or Any 6005 or 12650D Series Diagnostic Labor Operations)</TD><TD class=NOBOTTOMBORDER align=left>5.6 Hrs.</TD><TR><TD class=NOBORDER align=left>081613B</TD><TD class=NOBORDER align=left>2003-2004 Super Duty, 2003-2004 Excursion 6.0L Built Before 9/29/2003: Follow Pin Point Test KA In The PC/ED Manual. If It Leads To Turbocharger Replacement, Follow Service Procedure To Determine Turbocharger Repair, Perform Procedure To Clean Turbocharger, Includes Time To Remove Turbo For Inspection And Reinstall After Cleaning (Do Not Use With 6089A, 9438A Or Any 6005 or 12650D Series Diagnostic Labor Operations)</TD><TD class=NOBORDER align=left>6.4 Hrs.</TD><TR><TD class=NOBORDER align=left>081613C</TD><TD class=NOBORDER align=left>2003-2004 Super Duty, 2003-2004 Excursion 6.0L Built Before 9/29/2003: Follow Pin Point Test KA In The PC/ED Manual. If It Leads To Turbocharger Replacement, Follow Service Procedure To Determine Turbocharger Repair Perform Procedure To Replace CHRA, Includes Time To Remove Turbo For Inspection, Transfer The Necessary Parts To The New CHRA And Install (Do Not Use With 6089A, 9438A Or Any 6005 or 12650D Series Diagnostic Labor Operations)</TD><TD class=NOBORDER align=left>6.6 Hrs.</TD><TR><TD class=NOBORDER align=left>081613D</TD><TD class=NOBORDER align=left>2004-2007 Super Duty, 2004-2005 Excursion 6.0L Built On Or After 9/30/2003: Follow Procedure In This Article To Install The Vane Position Sensor Kit (VPS). If It Leads To Turbocharger Replacement, Follow Service Procedure To Determine Turbocharger Repair Turbo Damaged, Replace Turbocharger, Includes Time To Remove Turbo For Inspection, Transfer The VGT Control To The New Turbocharger And Install (Do Not Use With 6089A, 9438A Or Any 6005 or 12650D Series Diagnostic Labor Operations)</TD><TD class=NOBORDER align=left>3.1 Hrs.</TD><TR><TD class=NOBORDER align=left>081613E</TD><TD class=NOBORDER align=left>2004-2007 Super Duty, 2004-2005 Excursion 6.0L Built On Or After 9/30/2003: Follow Procedure In This Article To Install The VPS Kit. If It Leads To Turbocharger Replacement, Follow Service Procedure To Determine Turbocharger Repair Perform Procedure To Clean Turbocharger Includes Time To Remove Turbo For Inspection And Reinstall After Cleaning (Do Not Use With 6089A, 9438A Or Any 6005 or 12650D Series Diagnostic Labor Operations) </TD><TD class=NOBORDER align=left>3.7 Hrs.</TD><TR><TD class=NOBORDER align=left>081613F</TD><TD class=NOBORDER align=left>2004-2007 Super Duty, 2004-2005 Excursion 6.0L Built On Or After 9/30/2003: Follow Procedure In This Article To Install The Vane Position Sensor Kit (VPS). If It Leads To Turbocharger Replacement, Follow Service Procedure To Determine Turbocharger Repair Perform Procedure To Replace CHRA, Includes Time To Remove Turbo For Inspection, Transfer The Necessary Parts To The New CHRA And Install (Do Not Use With 6089A, 9438A Or Any 6005 or 12650D Series Diagnostic Labor Operations)</TD><TD class=NOBORDER align=left>4.0 Hrs.</TD><TR><TD class=NOBORDER align=left>081613G</TD><TD class=NOBORDER align=left>2004-2008 Econoline 6.0L Follow Procedure In This Article To Install The VPS Kit. If It Leads To Turbocharger Replacement, Follow Service Procedure To Determine Turbocharger Repair Turbo Damaged, Replace Turbocharger, Includes Time To Remove Turbo For Inspection, Transfer The VGT Control To The New Turbocharger And Install (Do Not Use With 6089A, 9438A Or Any 6005 or 12650D Series Diagnostic Labor Operations)</TD><TD class=NOBORDER align=left>4.0 Hrs.</TD><TR><TD class=NOBORDER align=left>081613H</TD><TD class=NOBORDER align=left>2004-2008 Econoline 6.0L Follow Procedure In This Article To Install The VPS Kit. If It Leads To Turbocharger Replacement, Follow Service Procedure To Determine Turbocharger Repair Perform Procedure To Clean Turbocharger, Includes Time To Remove Turbo For Inspection And Reinstall After Cleaning (Do Not Use With 6089A, 9438A Or Any 6005 or 12650D Series Diagnostic Labor Operations)</TD><TD class=NOBORDER align=left>4.6 Hrs.</TD><TR><TD class=NOBORDER align=left>081613J</TD><TD class=NOBORDER align=left>2004-2008 Econoline 6.0L Follow Procedure In This Article To Install The VPS Kit. If It Leads To Turbocharger Replacement, Follow Service Procedure To Determine Turbocharger Repair Perform Procedure To Replace CHRA. Includes Time To Remove Turbo For Inspection, Transfer The Necessary Parts To The New CHRA And Install (Do Not Use With 6089A, 9438A Or Any 6005 or 12650D Series Diagnostic Labor Operations)</TD><TD class=NOBORDER align=left>4.9 Hrs.</TD></TR></TBODY></TABLE>
DEALER CODING

<TABLE cellSpacing=0 cellPadding=3 border=1><TBODY><TR><TH align=middle>BASIC PART NO.</TH><TH align=middle>CONDITION CODE</TH></TR><TR><TD class=NOBOTTOMBORDER align=middle>6K682</TD><TD class=NOBOTTOMBORDER align=middle>42</TD></TR></TBODY></TABLE>
<HR>

 

08-11-3 May 08 COOLANT LOSS - 6.0L

<TABLE border=0><TBODY><TR><TD width=230>FORD:
</TD><TD>2003-2005 Excursion
2003-2007 F-Super Duty
2004-2008 E-Series</TD></TR></TBODY></TABLE>


This article supersedes TSB 08-3-7 to update the Service Procedure. ISSUE:


Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2008 E-Series vehicles, all equipped with a 6.0L engine, may exhibit:

• Coolant venting from the degas bottle cap
• No-crank/no-start
• Coolant leak
• White smoke from tail pipe
• Low coolant
• Lacks power overheat
• No cabin heat

The conditions typically occur when operating the vehicle under a load such as trailer towing, uphill driving, or both.
ACTION:

Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE



Prior to making any repairs, verify the coolant level is not overfull. The new coolant fill level is at the "MIN" line of the degas bottle cold. Overfilled coolant levels will cause coolant to vent from the degas bottle cap.
<TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>A FLOW CHART OF THIS PROCEDURE CAN BE FOUND AT THE END OF THE TSB. (FIGURES 9-11)</TD></TR></TBODY></TABLE>
Complete All Steps In Order As Outlined

1. Testing the degas bottle and pressure cap for proper operation of the pressure cap and its seal to the degas bottle:
   1. Do not remove the pressure cap.
   2. Install a pressure tester in-line with the degas bottle hose using Rotunda 014-R1068 adapter. (Figure 1)
      
      
      Figure 1 - Article 08-11-3
   3. Pressurize the cooling system by using slow and steady pump action on the tester pump handle. Quick or rapid pumps on the tester handle may cause false readings. Pressurize the system until the gauge pressure levels off, between 12-18 psi (83-124 kPa).
   4. The degas cap should release between 12-18 psi (83-124 kPa) allowing the pressure to level off.
      1. If the degas cap releases with less than 12 psi (83 kPa), replace the cap.
      2. If degas cap was replaced, apply pressure and wait 30 seconds for pressure to stabilize.
      3. If the gauge pressure drops:
         1. Apply soapy water around the cap to find any leaks.
         2. Check the degas bottle fill neck lip for nicks or cracks. Small nicks can be removed by light sanding with fine emery cloth.
         3. Re-pressure test, if leaks are still present replace the pressure cap if not already replaced in a previous step.
         4. Re-pressurize the system and test again, if leaks are still present replace the degas bottle, Refer to WSM, Section 303-03.
   5. After verifying that the degas bottle, pressure cap and cooling system are in good condition, proceed to Step 2.
2. EGR Cooler Leak Test On Vehicle:
   1. Install RADKITPLUSA 078-00592 on the degas tank.
   2. Regulate shop air to 100 psi (690 kPa) and apply vacuum to cooling system until gauge stops decreasing or 20 inches of vacuum is reached. (Degas bottle coolant level must be set to "MIN" line with a cold engine to allow sufficient space for vacuum.)
   3. Hold vacuum and allow vacuum to stabilize.
      1. If vacuum holds steady over 15 minutes proceed to Step 5.
      2. If vacuum does not hold steady over 15 minutes proceed to Step 3.
3. EGR Cooler Leak Test Off Vehicle:
   1. Remove the EGR cooler from the engine following Workshop Manual (WSM), Section 303-08.
   2. Install cooler block-off tools (Figure2) and pressurize the EGR cooler to 30 psi (207 kPa). Fasten the inlet and outlet port block-off plates using standard bolts, nuts and washers. (Figure 2)
      
      
      Figure 2 - Article 08-11-3
   3. Submerge the EGR cooler in water and inspect for bubbles.
      1. If bubbles identify a leak, replace the EGR cooler and proceed to Step 4.
      2. If bubbles do not identify a leak proceed to Step 4 and re-install the original EGR cooler.
4. Testing Oil Cooler:
   1. Gain access to the top of the oil cooler following WSM, Section 303-01C; only necessary steps since the EGR cooler is out of the vehicle. The test can be performed without removing the entire oil cooler from the engine.
   2. Apply the RADKITPLUSA as shown. (Figure 3) Regulate shop air to 100 psi (690 kPa) and apply vacuum to rear coolant port removing all residual coolant. The oil cooler must be free of coolant. Residual coolant will cause a false gauge reading.
   3. Stop the flow of shop air once the residual coolant has been removed.
   4. With the RADKITPLUSA still attached regulate shop air to 100 psi (690 kPa) and apply vacuum to rear coolant port. If RADKITPLUSA gauge needle moves from the rest / full stop position (indicating vacuum), replace the oil cooler. (Figure 3)
      
      
      Figure 3 - Article 08-11-3
      
      
      <TABLE border=0><TBODY><TR><TD></TD><TD width=100>CAUTION:</TD><TD>COOLANT ENTERING ANY COMBUSTION CHAMBER MAY CAUSE A HYDRO LOCK CONDITION. EVACUATE INTAKE PASSAGES AND COMBUSTION CHAMBERS OF ALL LIQUIDS USING A SUCTION DEVICE. REMOVE GLOW PLUGS (REFER TO WSM, SECTION 303-07B) TO ASSIST IN VENTING LIQUID FROM COMBUSTION CHAMBERS, BEFORE ENGINE IS STARTED.</TD></TR></TBODY></TABLE>
   5. Re-assemble engine, fill the cooling system, perform Step 5a - 5e and proceed to Step 6b.
5. Road Test Setup And Observations:
   1. Install the IDS PVT, or Rotunda Pressure Adapter Kit 014-00761, or equivalent. (Figure 4)
      
      
      Figure 4 - Article 08-11-3
   2. Carefully release the cooling system pressure, leaving the tester in place.
   3. Seal pressure bleed.
   4. Drive the vehicle at wide open throttle (WOT) / high load / maximum boost.
   5. Observe whether the cooling system pressure exceeds the holding pressure of 12-18 psi (83-124 kPa) noted in Step 1.
   6. Check for coolant venting through the degas bottle cap by listening for a hissing noise.
   7. Observe ECT and EOT PID's on IDS Datalogger. EOT maximum temperature differential might occur at throttle tip-out.
6. Road Test Evaluation:
   Follow IDS PVT Datalogger instructions on screen.
   1. If EOT is within 25 degrees of the ECT and the cooling system pressure is less than the holding pressure as noted in Step 1 proceed to Step 7.
   2. If EOT exceeds ECT by 25 degrees at any time during the test, replace the oil cooler and leak check the EGR cooler off vehicle using procedure in Step 3. Repeat Step 5 following oil cooler replacement.
      <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>DO NOT REPLACE HEAD GASKETS IF COOLING SYSTEM PRESSURE EXCEEDS DEGAS CAP HOLDING PRESSURE WHEN EOT EXCEEDS ECT BY 25 DEGREES.</TD></TR></TBODY></TABLE>
   3. If the cooling system pressure is greater than the holding pressure noted in Step 1, and/or the degas bottle cap continuously vents when loading the engine and the EOT is within 25 degrees of the ECT, perform PC/ED Cooling System Diagnostics for the Vistronic Fan Clutch. If Vistronic Fan Clutch passes or has been replaced continue to Step 8. If Vistronic Fan Clutch fails replace the Vistronic Fan Clutch and repeat Step 5.
   4. If the EGR cooler passes the off-engine leak check, if no other leaks are found and if cooling system pressure is greater than the holding pressure noted in Step 1, and/or the degas bottle cap continuously vents with loaded engine, perform PC/ED Cooling System Diagnostics for the Vistronic Fan Clutch. If Vistronic Fan Clutch passes or has been replaced continue to Step 8. If Vistronic Fan Clutch fails replace the Vistronic Fan Clutch and repeat Step 5.
   5. If the EOT is within 25 degrees of the ECT and the cooling system pressure is less than the holding pressure noted is step 1 proceed to Step 9.
      <TABLE border=0><TBODY><TR><TD></TD><TD width=100>CAUTION:</TD><TD>CAREFULLY RELEASE THE COOLING SYSTEM PRESSURE WHILE REMOVING DEGAS CAP.</TD></TR></TBODY></TABLE>
7. On Vehicle EGR Cooler Leak Test With Engine Warm:
   1. Install RADKITPLUSA on the degas tank.
   2. Regulate shop air to 100 psi (690 kPa) and apply vacuum to cooling system until gauge stops decreasing or 20 inches of vacuum is reached. (Degas bottle coolant level must be set to "MIN" line with a cold engine to allow sufficient space for vacuum.)
   3. Hold vacuum and allow vacuum to stabilize.
   4. If vacuum holds steady over 15 minutes proceed to Step 6c-e.
   5. If vacuum does not hold steady over 15 minutes proceed to Step 3 and 4 to test the EGR Cooler off the vehicle and testing oil cooler on vehicle.
8. Head Gasket Replacement:
   1. Refer to WSM, Section 303-01C for head removal/installation and head flatness specification and replace the head gaskets.
   2. Check the surface of the heads for flatness and/or imperfections. Refer to WSM, Section 303-00 for the REVISED cylinder head flatness measuring procedures.
   3. Use the following revised head bolt torque sequence and specifications. (Figure 5) Refer to TSB 07-10-4 for cylinder head identification.
      
      
      Figure 5 - Article 08-11-3
      
      
      <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>THE CYLINDER HEAD MUST BE CLEANED PRIOR TO CHECKING FOR FLATNESS OR YOU WILL GET IMPROPER READINGS.</TD></TR></TBODY></TABLE>
      
      <TABLE border=0><TBODY><TR><TD></TD><TD width=100>CAUTION:</TD><TD>IF THE INJECTORS ARE LEFT IN THE CYLINDER HEADS DURING THE REMOVAL OR INSTALLATION PROCESS INJECTOR DAMAGE CAN OCCUR.</TD></TR></TBODY></TABLE>
   4. Cylinder Head Handling Tips.
      • Avoid banging, dragging or scratching the cylinder head at all times. When removing the cylinder head, lift the cylinder head straight up off of the dowels so as not to nick the cylinder head.
      • Once the cylinder head is removed, place the cylinder head on a bench with the gasket side up. If the gasket surface must be turned down, use a piece of clean cardboard on the bench surface to protect the cylinder head from damage. Do not allow the cylinder head to slide on the gasket surface, even on cardboard.
   5. Cleaning Cylinder Head Deck Surface.
      The only tools approved by Ford Motor Company for cleaning the cylinder head and deck surface are plastic (Figure 6) and wood scrapers, combined with the use of Motorcraft®Metal Surface Prep. Ensure that the mating cylinder block deck surface is completely free of solid contamination, corrosion, and fluids.
      <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>STAINING OF THE METAL SURFACE IS CONSIDERED NORMAL AND DOES NOT AFFECT SEALING ABILITY.</TD></TR></TBODY></TABLE>
      
      <TABLE border=0><TBODY><TR><TD></TD><TD width=100>CAUTION:</TD><TD>DO NOT CLEAN DECK SURFACES UNDER ANY CIRCUMSTANCE WITH STEEL RAZOR BLADES, ROTARY ABRASIVE DEVICES, OR ABRASIVES INCLUDING: ROLOC™ AND 3M BRANDED SCOTCHBRITE™ PRODUCTS OR EQUIVALENTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVES SUCH AS SANDPAPER OR EMERY CLOTH, ANY CARBON STEEL BLADE. THESE PRODUCTS WILL CUT AND DAMAGE DECK SURFACES RESULTING IN LEAKS. ABRASIVE PARTICLES MAY ALSO ENTER THE ENGINE CAVITIES CAUSING INTERNAL ENGINE DAMAGE. USE OF THESE TOOLS CAN ALSO GREATLY AFFECT THE FLATNESS OF THE SURFACE.</TD></TR></TBODY></TABLE>
      
      
      Figure 6 - Article 08-11-3
      
      
9. Vehicle Assembly:
   1. If the oil cooler, EGR cooler, or head gaskets have been replaced, flush the cooling and heater system together using Motorcraft® Premium Cooling System Flush.
   2. Use RADKITPLUSA 078-00592 to fill cooling system. Refer to WSM 303-03.
   3. Change engine oil and oil filter.
      <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>ON 2004 E-SERIES 6.0L BUILT BEFORE 05/29/2004: IF THE OIL COOLER IS REPLACED, ALSO REPLACE THE HEATER CORE INLET HOSE; THE REVISED HOSE CONTAINS AN INTERNAL FLOW RESTRICTOR (FIGURE 7). REFER TO TSB 05-2-5 FOR ADDITIONAL INFORMATION.</TD></TR></TBODY></TABLE>
      
      
      Figure 7 - Article 08-11-3
      
      
   4. Remove the EBP sensor wire connector and inspect weather seal. If the seal is missing, replace the connector and EBP sensor.
   5. Check for diagnostic trouble codes (DTCs). Perform the following inspection and tests.
      1. For 2004 (built after 9/29/03) - 2006 F-Super Duty and 2004 (built after 9/29/03) - 2005 Excursion: reprogram the powertrain control module (PCM) to the latest calibration using IDS release B39.12 and higher. This calibration contains a revised cooling fan strategy to help reduce the occurrence of coolant venting. Calibration files may also be obtained at MOTORCRAFT PARTS FOR FORD, LINCOLN OR MERCURY VEHICLES.
   6. Perform Turbo Boost Test.
      1. If test FAILS refer to PC/ED Turbo Diagnostic Pinpoint Test KA for further details.
      2. If test passes, repairs complete.
         <TABLE border=0><TBODY><TR><TD width=80>NOTE:</TD><TD>OVER-BOOST CONDITIONS (HIGHER THAN SPECIFIED MGP) WILL RESULT IN EXCESSIVE CYLINDER PRESSURES, AND MAY BE CAUSED BY ONE OF THE FOLLOWING: IRREGULAR RESPONSE IN VARIABLE GEOMETRY TURBO, BIASED EXHAUST PRESSURE SENSOR, AND/OR IRREGULAR EXHAUST GAS RECIRCULATION.</TD></TR></TBODY></TABLE>

<TABLE cellSpacing=0 cellPadding=3 border=1><TBODY><TR><TH align=middle>PART NUMBER</TH><TH align=middle>PART NAME</TH></TR><TR><TD class=NOBOTTOMBORDER align=left>3C3Z-9P456-AE</TD><TD class=NOBOTTOMBORDER align=left>EGR Cooler (Built Before 9/29/2003)</TD></TR><TR><TD class=NOBORDER align=left>4C3Z-9P456-AF</TD><TD class=NOBORDER align=left>EGR Cooler (Built 9/29/2003 And After)</TD></TR><TR><TD class=NOBORDER align=left>3C3Z-6A642-AA</TD><TD class=NOBORDER align=left>Oil Cooler</TD></TR><TR><TD class=NOBORDER align=left>7C2Z-18472-A</TD><TD class=NOBORDER align=left>Hose - Inlet Heater Core (E-Series)</TD></TR><TR><TD class=NOBORDER align=left>6C3Z- 8A080-B</TD><TD class=NOBORDER align=left>Degas Bottle (F-Series)</TD></TR><TR><TD class=NOBORDER align=left>4C2Z-8A080-AA</TD><TD class=NOBORDER align=left>Degas Bottle (E-Series)</TD></TR><TR><TD class=NOBORDER align=left>4C2Z-18476-AA</TD><TD class=NOBORDER align=left>Heater Core (E-Series)</TD></TR><TR><TD class=NOBORDER align=left>4C3Z-18476-BA</TD><TD class=NOBORDER align=left>Heater Core (F-Series, Excursion)</TD></TR><TR><TD class=NOBORDER align=left>F6DZ-8100-A</TD><TD class=NOBORDER align=left>Cap - Degas Bottle</TD></TR><TR><TD class=NOBORDER align=left>VC-1</TD><TD class=NOBORDER align=left>Motorcraft® Premium Cooling System Flush</TD></TR><TR><TD class=NOBORDER align=left>ZC-31-A</TD><TD class=NOBORDER align=left>Motorcraft®Metal Surface Prep</TD></TR><TR><TD class=NOBORDER align=left>3C3Z-9E933-BA</TD><TD class=NOBORDER align=left>Gasket Front EGR Cooler</TD></TR><TR><TD class=NOBORDER align=left>3C3Z-9E933-AA</TD><TD class=NOBORDER align=left>Gasket Rear EGR Cooler</TD></TR><TR><TD class=NOBORDER align=left>3C3Z-6A831-AA</TD><TD class=NOBORDER align=left>O-Ring Oil Filter Housing</TD></TR><TR><TD class=NOBORDER align=left>3C3Z-9A375-AA</TD><TD class=NOBORDER align=left>Washer Fuel Banjo</TD></TR><TR><TD class=NOBORDER align=left>3C3Z-9J469-AA</TD><TD class=NOBORDER align=left>O-Ring Heater Tube Front </TD></TR><TR><TD class=NOBORDER align=left>3C3Z-9229-AA</TD><TD class=NOBORDER align=left>O-Ring Kit Injector</TD></TR><TR><TD class=NOBORDER align=left>3C3Z-6051-CA</TD><TD class=NOBORDER align=left>Head Gasket Kit Built Before 10/2003 (Figure 8 For Application)</TD></TR><TR><TD class=NOBORDER align=left>6C3Z-6051-A</TD><TD class=NOBORDER align=left>Head Gasket Kit 20 mm Align Dowels (Figure 8 For Application)</TD></TR><TR><TD class=NOBORDER align=left>4C3Z-6051-EA</TD><TD class=NOBORDER align=left>Head Gasket Kit 18 mm Align Dowels (Figure 8 For Application)</TD></TR><TR><TD class=NOBORDER align=left>4C3Z-6051-DA</TD><TD class=NOBORDER align=left>Head Gasket Kit Over Size (Figure 8 For Application) </TD></TR></TBODY></TABLE>




Figure 8 - Article 08-11-3


OTHER APPLICABLE ARTICLES:

07-10-4, 05-2-5
WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
<TABLE cellSpacing=0 cellPadding=3 border=1><TBODY><TR><TH align=middle>OPERATION</TH><TH align=middle>DESCRIPTION</TH><TH align=middle>TIME</TH></TR><TR><TD class=NOBOTTOMBORDER align=left>081103A</TD><TD class=NOBOTTOMBORDER align=left>2004-2008 Econoline 6.0L: Includes Time To Install Pressure Tester In-line with Degas Bottle and Pressurize the Cooling System Several Times. Install Radkitplus on the Degas Tank to Test The EGR Cooler On Vehicle Twice, Replace the Degas Cap if Required, Sand Degas Bottle Fill Neck to Remove Small Nicks if Required. Install IDS/PVT, Road Test(s), Diagnosis of Fan Clutch, Check for DTC’s, Reprogram PCM to the latest Calibration and Perform Turbo Boost Test (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38) This Labor Operation May be Claimed With Operations B, C, D, E, F and G. </TD><TD class=NOBOTTOMBORDER align=left>2.3 Hrs.</TD><TR><TD class=NOBORDER align=left>081103A</TD><TD class=NOBORDER align=left>2003 Super Duty, 2003 Excursion 6.0L: Includes Time To Install Pressure Tester In-line with Degas Bottle and Pressurize the Cooling System Several Times. Install Radkitplus on the Degas Tank to Test The EGR Cooler On Vehicle Twice, Replace the Degas Cap if Required, Sand Degas Bottle Fill Neck to Remove Small Nicks if Required. Install IDS/PVT, Road Test(s), Diagnosis of Fan Clutch, Check for DTC’s, Reprogram PCM to the latest Calibration and Perform Turbo Boost Test (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38) This Labor Operation May be Claimed With Operations B, C, D, E, F and G. </TD><TD class=NOBORDER align=left>2.3 Hrs.</TD><TR><TD class=NOBORDER align=left>081103A</TD><TD class=NOBORDER align=left>2004-2007 Super Duty, 2004-2005 Excursion 6.0L: Includes Time To Install Pressure Tester In-line with Degas Bottle and Pressurize the Cooling System Several Times. Install Radkitplus on the Degas Tank to Test The EGR Cooler On Vehicle Twice, Replace the Degas Cap if Required, Sand Degas Bottle Fill Neck to Remove Small Nicks if Required. Install IDS/PVT, Road Test(s), Diagnosis of Fan Clutch, Check for DTC’s, Reprogram PCM to the latest Calibration and Perform Turbo Boost Test (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38) This Labor Operation May be Claimed With Operations B, C, D, E, F and G. </TD><TD class=NOBORDER align=left>2.3 Hrs.</TD><TR><TD class=NOBORDER align=left>081103B</TD><TD class=NOBORDER align=left>2004-2007 Super Duty, 2004-2005 Excursion 6.0L: Includes Time To Remove and Leak Check EGR Cooler off Engine, Test Oil Cooler Using Radkitplus, Replace EGR Cooler And/Or Oil Cooler if Required, Time to Flush and Fill Cooling System, Change Engine Oil and Filter. (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38) May be Claimed With Operations A, C, D, E, F and G. </TD><TD class=NOBORDER align=left>6.5 Hrs.</TD><TR><TD class=NOBORDER align=left>081103B</TD><TD class=NOBORDER align=left>2003 Super Duty, 2003 Excursion 6.0L: Includes Time To Remove and Leak Check EGR Cooler off Engine, Test Oil Cooler Using Radkitplus, Replace EGR Cooler And/Or Oil Cooler if Required, Time to Flush and Fill Cooling System, Change Engine Oil and Filter (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38) May be Claimed With Operations A, C, D, E, F and G. </TD><TD class=NOBORDER align=left>5.9 Hrs.</TD><TR><TD class=NOBORDER align=left>081103B</TD><TD class=NOBORDER align=left>2004-2008 Econoline 6.0L: Includes Time To Remove and Leak Check EGR Cooler off Engine, Test Oil Cooler Using Radkitplus, Replace EGR Cooler And/Or Oil Cooler if Required, Time to Flush and Fill Cooling System, Change Engine Oil and Filter (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38) May be Claimed With Operations A, C, D, E, F and G</TD><TD class=NOBORDER align=left>8.2 Hrs.</TD><TR><TD class=NOBORDER align=left>081103C</TD><TD class=NOBORDER align=left>2004-2008 Econoline 6.0L: Replace The Degas Bottle if Required (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, D, E, F and G. </TD><TD class=NOBORDER align=left>0.4 Hr.</TD><TR><TD class=NOBORDER align=left>081103C</TD><TD class=NOBORDER align=left>2004-2007 Super Duty, 2004-2005 Excursion 6.0L: Replace The Degas Bottle if Required (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, D, E, F and G. </TD><TD class=NOBORDER align=left>0.5 Hr.</TD><TR><TD class=NOBORDER align=left>081103C</TD><TD class=NOBORDER align=left>2003 Super Duty, 2003 Excursion 6.0L: Replace The Degas Bottle if Required(Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, D, E, F and G. </TD><TD class=NOBORDER align=left>0.5 Hr.</TD><TR><TD class=NOBORDER align=left>081103D</TD><TD class=NOBORDER align=left>2004-2007 Super Duty, 2004-2005 Excursion 6.0L: Replace Fan Clutch if Required (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, C, E, F and G. </TD><TD class=NOBORDER align=left>1.1 Hrs.</TD><TR><TD class=NOBORDER align=left>081103D</TD><TD class=NOBORDER align=left>2004-2008 Econoline 6.0L: Replace Fan Clutch if Required (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, C, E, F and G. </TD><TD class=NOBORDER align=left>1.7 Hrs.</TD><TR><TD class=NOBORDER align=left>081103D</TD><TD class=NOBORDER align=left>2003 Super Duty, 2003 Excursion 6.0L: Replace Fan Clutch if Required (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, C, E, F and G. </TD><TD class=NOBORDER align=left>1.1 Hrs.</TD><TR><TD class=NOBORDER align=left>081103E</TD><TD class=NOBORDER align=left>2003 Super Duty, 2003 Excursion 6.0L: Replace Head Gaskets. Includes Time to Remove Clean and Check Cylinder Heads for Flatness (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, C, D, F and G </TD><TD class=NOBORDER align=left>13.6 Hrs.</TD><TR><TD class=NOBORDER align=left>081103E</TD><TD class=NOBORDER align=left>2004-2007 Super Duty, 2004-2005 Excursion 6.0L: Replace Head Gaskets. Includes Time to Remove Clean and Check Cylinder Heads for Flatness (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, C, D, F and G. </TD><TD class=NOBORDER align=left>14.1 Hrs.</TD><TR><TD class=NOBORDER align=left>081103E</TD><TD class=NOBORDER align=left>2004-2008 Econoline 6.0L: Replace Head Gaskets. Includes Time to Remove Clean and Check Cylinder Heads for Flatness (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, C, D, F and G</TD><TD class=NOBORDER align=left>19.8 Hrs.</TD><TR><TD class=NOBORDER align=left>081103F</TD><TD class=NOBORDER align=left>2004-2008 Econoline 6.0L: Replace EBP Sensor And Connector if Required (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38) May be Claimed With Operations A, B, C, D, E and G. </TD><TD class=NOBORDER align=left>0.7 Hr.</TD><TR><TD class=NOBORDER align=left>081103F</TD><TD class=NOBORDER align=left>2004-2007 Super Duty, 2004-2005 Excursion 6.0L: Replace EBP Sensor And Connector if Required (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38) May be Claimed With Operations A, B, C, D, E and G. </TD><TD class=NOBORDER align=left>0.7 Hr.</TD><TR><TD class=NOBORDER align=left>081103F</TD><TD class=NOBORDER align=left>2003 Super Duty, 2003 Excursion 6.0L: Replace EBP Sensor And Connector if Required (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38) May be Claimed With Operations A, B, C, D, E and G. </TD><TD class=NOBORDER align=left>0.7 Hr.</TD><TR><TD class=NOBORDER align=left>081103G</TD><TD class=NOBORDER align=left>2003 Super Duty, 2003 Excursion 6.0L: Remove Glow Plugs to Vent Liquid from Combustion Chambers Should Only Be Claimed If Engine Is Found To Be Hydro-locked (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, C, D, E and F.</TD><TD class=NOBORDER align=left>1.4 Hrs.</TD><TR><TD class=NOBORDER align=left>081103G</TD><TD class=NOBORDER align=left>2004-2007 Super Duty, 2004-2005 Excursion 6.0L: Remove Glow Plugs to Vent Liquid from Combustion Chambers, Should Only Be Claimed If Engine Is Found To Be Hydro-locked (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, C, D, E and F. </TD><TD class=NOBORDER align=left>1.4 Hrs.</TD><TR><TD class=NOBORDER align=left>081103G</TD><TD class=NOBORDER align=left>2004-2008 Econoline 6.0L: Remove Glow Plugs to Vent Liquid from Combustion Chambers Should Only Be Claimed If Engine Is Found To Be Hydrolocked (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38). May be Claimed With Operations A, B, C, D, E and F. </TD><TD class=NOBORDER align=left>2.2 Hrs.</TD><TR><TD class=NOBORDER align=left>081103H</TD><TD class=NOBORDER align=left>2004 - Econoline 6.0L Build Before 5-29-04: Replace Heater Core Inlet Hose (Do Not Use With 6642A, 8080A, 8005D, 9456A, 8616A, 12342D1, 6051A, 6005F12, 6005F38)May be Claimed With Operations A, B, C and D. </TD><TD class=NOBORDER align=left>0.5 Hr.</TD></TR></TBODY></TABLE>
DEALER CODING

<TABLE cellSpacing=0 cellPadding=3 border=1><TBODY><TR><TH align=middle>BASIC PART NO.</TH><TH align=middle>CONDITION CODE</TH></TR><TR><TD class=NOBOTTOMBORDER align=middle>6051</TD><TD class=NOBOTTOMBORDER align=middle>42</TD></TR></TBODY></TABLE>


Figure 9 - Article 08-11-3




Figure 10 - Article 08-11-3




Figure 11 - Article 08-11-3




Figure 12 - Article 08-11-3

 

GREAT INFORMATION, THANKS!!!

Ironically I just picked up my F-350 from the dealer, it was in for coolant loss and fan noise. The above TSB 8-11-03 was also referenced on my Invoice, plus TSB 08-18-06??.

I got all kind of new goodies, New Fan Clutch, New Belt, Head gaskets, ARP studs, Oil Cooler, Injector Pressure Regulator, HPOP fitting Kit, EGR Cooler, all the screens in and around the oil cooler/HPOP and more (3 pages worth of parts) all under warranty!

Runs like a new truck and no more crazy fan noise!!! Ran the crap out of it on the way home going up in the mountains where I live.... and for the first time since I have owned it I opened the hood and there was coolant up to the full mark in the degass bottle!!!!

Life is good... for the moment :-)

 

Yes, thanks Mark. I wish I was as happy as FTX. I hooked up my 15k fiver today and pulled a grade of about 6%. Steam whistle sounded about 3/4 of the way up but no coolant loss. Took it back to the dealer and the Service Manager agreed to ride with me. He hooked up a diagnostic computer to the truck. We pulled the same grade. About 1/2 way up there was a loud boom and steam and coolant came pouring out from under the hood. Pulled over, lifted hood and the big alum. pipe on top had blown off and took with it a smaller rubber tube with coolant in it. The coolant was pumping out like blood out of an artery. Seems a clamp had broken. Looked to me like it had a weak spot and the tech yesterday tightened it too much. Anyway, they got some coolant and new clamps. Re-attached everything. I drove it to my house, unhooked the fiver and waived to the Service Manager as he drove off with my truck. I'm determined to get this fixed permanently before we head to AZ for the winter. I'll keep you'all posted on results.

 

Glad to help Candrew. I wish you well w/ your truck issues.

 

Good info, Thanks.

 

A follow up since my truck had some of these TSBs just done this week. I took it on a 500 mile trip towing a car hauler with car on it. Ran like a champ and never missed a beat AND never made a single "funny noise". Cooling fan never came on even going up steep mountain roads (used to come on all the time and oscillate and squeal like crazy before) AND I had the same amount of coolant when I returned that I had when I left!!! First time ever this has happened since I have owned it.

(fingers crossed)

 

Also as a follow-up. I got my truck back last week. Had a chance today to hook up my 15k fiver and pull a 6% grade a couple of times. Perfect! Purred like a kitten...took it easy at 45mph with a 28 psi boost. No steam whistle and no puking. What a relief! Now ready to go south next month.

 

Yep, Same here.. took it on a few more trips pulling my Toy Hauler up the toughest climbs I will probably ever have to do in this area...2800' elevation change in less than 10 miles on a tight curvy 2 lane road (don't know the grade). Went as fast as I wanted to and would have easily gone faster if the curves weren't so tight. Definitely could have gotten a speeding ticket in the 45 mph zone in some of the straighter sections. :-)

Other than a bad battery it has been flawless since these latest TSBs were done! I just finished my install of the Magnaflow 4" Turbo-back yesterday and ready to go at it again!