I had the same problem with my truck. as I was driving the CEL came on and it started jerking. thought it was going to throw me out of the truck. Pulled the valve covers and had two places where the harness was burnt clean through.

 

ok i got the o rings but had to order the gaskets when i do this do i need to rub oil on the orings and use gasket sealer like permatex or somethin on the gaskets

 

This is from my Ford Shop Manual. (I do not remove the fan, fan clutch assembly, fan shroud or belt) I use "Ultra RTV" on the two gaskets.

Removal

1. Drain the engine coolant.

2. Remove the upper radiator hose clamps and the upper radiator hose (8260).

3. Disconnect the radiator coolant recovery reservoir hose at the radiator (8005).

4. Remove the fan and clutch assembly using Fan Clutch Nut Wrench T83T-6312-
B and Fan Clutch Pulley Holder T94T-6312-AH, set fan and clutch assembly in
fan shroud (8146).

5. Remove the two fan shroud screws.

6. Remove the fan shroud, and fan and clutch assembly.

7. Remove the drive belt (8620).

8. Remove the water pump inlet retaining bolts and water pump inlet.

9. Remove the oil cooler front header retaining bolts.

10. Remove the marmon clamp from the turbocharger exhaust outlet pipe.

11. Raise vehicle.

12. Remove the oil filter.

13. Remove the engine block heater electrical connector.

14. Remove the two left engine mount to bracket bolts.

15. Reposition the engine assembly using a suitable jack.

16. Remove the oil cooler rear header retaining bolts, engine oil cooler (6A642) and
gaskets.


Installation

1. Install the engine oil cooler, rear gasket and three rear bolts to snug.

2. Lower the engine in its original position.

3. Install two engine mount to bracket bolts, tighten bolts to standard torque
specification listed at the end of this section.

4. Lower vehicle.

5. Install the oil cooler front header gasket and two retaining bolts. Tighten bolts
to 32 N-m (24 lb-ft).

6. Raise vehicle.

7. Tighten the three oil cooler rear header retaining bolts to 19 N-m (14 lb-ft).

8. Install the oil filter.

9. Connect the engine block heater electrical connector.

10. Lower vehicle.

11. Install the water pump inlet and two retaining bolts, tighten bolts to 20N-m (15 lb-ft).

12. Install the drive belt.

13. Install the fan shroud, and fan and clutch assembly.

14. Install the fan shroud retaining screws and tighten screws to 5-8 N-m (44-71
lb-in).

15. Install the fan and clutch assembly using Fan Clutch Nut Wrench T83T-6312-B
and Fan Clutch Pulley Holder T94T-6312-AH.

16. Install the radiator coolant recovery reservoir hose to the radiator.

17. Install the upper radiator hose and hose clamps.

18. Refill the engine cooling system.

19. Refill the engine oil.

 

WOW ok guys i got my oil cooler out put new o rings in it and new gaskets and now my truck doesnt leak a drop of oil i owe you guys much gratitude i cant thank you enough that massive oil leak has bothered me so long but not any more I THANK ALL OF YOU

 

Glad that you got it fixed. Now you can help the next guy that has this problem.

 

Glad you got it done. Congrats.