Sudden Major Oil leak top rear of the 6.0
 

On a 2003 6.0L w/ ~200K Major oil leak erupted. Unfortunately I didn't dye the oil before I took it apart. Symptoms:
Lost at least 2 quarts rather quick, smoke around Turbo due to oil at up pipe/exhaust. from underneath oil observed above heads and coming from rear of motor area both sides. Valley of motor damp.

• Pulled Turbo: Not supply or drain line.
• Pulled Intake (because I will ******can EGR cooler) no culprits there.
• Pulled Oil cooler (time to replace) no issue noted.
• Pulled HPOP cover. Gasket at rear could be an issue, but no obvious blowout. ICP and IPR have not been pulled off of the HPOP cover yet.

I am guessing that the sudden failure with such a large leak at the back top of the motor is a dead giveaway to someone.

Q1: What is the culprit?
Q2: Besides the EGR cooler delete and new Oil cooler, any recommendations of items to service while I have the valley opened up?
Q3: Anything special about the gray sealant at the back of the HPOP cover I should know about?

Thanks in advance.

I had a good oil leak like that about a year back on my 03 6.0, It ended up being my ICP sensor. Changed that and put the new pigtails on and it was good to go. Id probably look there first if it was me.

ditto on the icp. happened to me.

bump icp sensor. if it was puking oil then replace the connector as well

ICP also. Common on 03 and early 04's.

I had the same type of leak on my Ex at 89,713 miles. It was down the back of the engine all the way to the back bumper, even the front of my horse trailer had a fine coat of synthetic motor oil on it. When I checked oil level was only down 2+ quarts. Took it into dealer they said it was the ICP shorting out and leaking.

ICP 3C3Z-9F838-EA SENSOR 925977 $148.47

OIL CHANGE AND FILTER

Total bill parts and labor: $766.12

(Labor $463.80)

and they did not even offer to or ask me if I wanted to upgrade the oil drain pipe on the Turbo while they had it torn apart.

Hope this helps.

sorry to be the one to tell you but there is no reason to remove the turbo to change the icp sensor on an 03/ early 04.
to remove them you go from under the truck and remove the heat sheild thats in front of the Y-pipe and its right there. ford pays .7 under warranty to r/i plus diag.

No problem on the Turbo...I planned on a EGR cooler delete.
(Just finished cutting the ends off the cooler to make blocker plates and fabing a new coolant bypass tube ).

Oil leak was the ICP. O-ring disintegrated!! Thanks to all of the advice.

As mentioned above, I will put a new oil cooler in while the top is off.

I will take 03-6L-X's advice and upgrade the oil drain tube.

Anything else I should consider while I'm laying on top of the motor?

Thanks again.

don't forget to use dielectric grease on the icp connector.

there is also an updated suply tube as well

ATGLLC:
Here is some more information on the 6.0. It also gives you the part numbers for some of the upgrades you are looking to do. Good luck hope this helps.



6.0L Ford Power Stroke Engine - Ford Diesel Trucks - Diesel Power Magazine

Thanks again to all !
Based on the comments and the references I plan to:

• Thorough cleaning including the sumps
• EGR cooler delete
• Replace oil cooler
• Updated Turbo supply and drain lines
• HPOP o-rings kit (looks like no STC issue for 2003)
• New ICP w/dielectric grease and pigtail

Please let me know if I missed anything important. I prefer to stay away from the valley of the motor for another 200K if possible.

New sump screen under the oil cooler