Ford 6.0L Power Stroke Diesel :: Coolant Leak From EGR Cooler O-Ring
Apr 17, 2016
I installed a BPD EGR cooler about 4 years ago just as a preventative measure (along with an oil cooler) in my '06 F-250 6.0. About 6 months ago some coolant was found to be coming down the rear of the engine and onto the garage floor but only in the mornings after cooling down and even then not every morning.
A couple weeks ago I did a coolant flush and put the red ELC coolant in and now I can see better where the coolant is coming from. It appears to be coming out from the O-ring between the cooler and the intake manifold. I did check the torque on the stud and bolt and they are tight.
Is there a way the drop the cooler enough to install a new O-ring with out going through the whole process of removing the intake manifold and everything that is associated with that? The thought is daunting...
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Truck has never been flushed. Would you try and back flush through oil cooler or just do a regular flush according to the procedure in the tech folder?
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I'm getting pretty comfortable with these forums now. Not sure if this is in the right section, but even if it was, I'm not sure how to find the right one. I recently purchased Bullet Proof Diesel's Air-to-Oil oil cooler along with the BPD oil filtration. I've already drained the oil, but do I need to drain the coolant as well? I have read of people doing a complete flush before even installing a new oil cooler (OEM oil cooler). That way once it is installed, it doesn't have all the grit and sand pumping through it right off the bat. But does it matter with BPD's system? Should I go ahead and drain the coolant completely before beginning this job?
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I just had my oil cooler and EGR cooler replaced, and I'm now consider doing a coolant flush with Restore/Restore+ to ensure the coolant system is clean. I know this might be backwards and perhaps should have done the flush first, but schedule and such did not allow. I do have a coolant filter.
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2 1/2 years ago I installed a BPD remote oil cooler with BPD filter. The stock oil cooler was clogging up for the second time and didnt want to chance it. The BPD oil cooler works great. I have never seen high oil temps in any driving condition. Last week I was replacing the hubs and seals on the front of the excursion and noticed the oil was leaking from the 90 at the end of the hose oil filter location. I called BPD and sent them a picture. The 90 is corroded and is failing. They said something about a 2 year warranty but because of the rust they would not send one out for free. I purchased a new hose and the other 90 that goes right after it.
They recommended that I spray it with undercoating or something. I live in upstate NY and deal with a lot of salt on the roads in winter. I do keep the truck clean in winter as much a possible. I am posting this so if there are any others in similar situation you should do something to prevent that 90 from rusting like mine did. If I had known this when we installed it prob would not be replacing it now. Will be replacing it tonight or tomorrow. BPD said I will need a 1 1/4 crow foot or remove the turbo to get to the other end of the hose. Not posting this to bash on BPD just sharing so any others can prevent this part from rusting out.
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I have a 2005 F250 with 6.0 and almost 175,000. On vacation right now and noticed when I came out of a store that there was a puddle of water under the passengers side. Chalked it up to AC defrost. The second time I was not running AC and puddle again.
Felt and smelt of it...antifreeze. Just put in all new Zerex G05 and a new degas tank because when working on it I noticed a pin hole in the base before we left. I replaced the EGR cooler and hose from Sinister about 3 plus years ago.
Would the EGR cooler hose be leaking? I've noticed that white residue on top of the intake around the where the hose is. What would cause this, Heat, wear and tare....my luck ?
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I I have a pretty good o ring leak where the egr cooler meets with the intake. My question is can i replace the o ring without removing​ the intake. If so what is the process.
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Just bought a 2005 F250 PSD, got a smoking deal on it. It has 321k miles and has been very well taken care of however I do believe that it either needs a new oil cooler or has bad head gaskets. Pictured below you will see what the coolant looked like when I let the first batch lose. It does not seem foamy, which is interesting to me, however there is NO EGR to cause this soot.
About the truck:
- It was bulletproofed at 50k miles (EGR delete, ARP head studs, etc).
- There is no puking of coolant (drove it 100 miles from where I purchased it and nothing)
- When the truck is started you have to let it warm up for about 10 minutes,otherwise it seems to not have full power. (was going to reflash the ECU in hopes this repaired that problem).
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I am doing the usual upgrades on a 2005 F250. What started as a small leak at the rubber coupling between egr tube and oil cooler turned into doing everything else while motor is down this far.
I am curious what the difference in the upgraded oil cooler is? Well besides not prone to failing as early.
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Can I change these out to hydraulic hoses with clamps that are rated for the fluid. Mine are rusted and starting to leak.
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My buddy install a BPD air/oil oil cooler in his 2003 F250 last week and now there is coolant pouring out the tail pipe. I haven't seen it but he tells me there is quite a bit coming out. It wasn't doing this before we installed the BPD oil cooler. Normally I would say bad EGR cooler but his EGR is deleted. This is the 3rd BPD cooler I've put in and this is the first time I've had any issues after the install. The install went smooth other than we broke the radiator and had to install a new one. I feel bad cause I'm hoping it wasn't something I caused but I just can't think of anything I did during this install that would cause coolant to be getting into the exhaust. He just had it towed to the local Ford dealership.
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I have a 04 that has 153k on it. 4" cat back exhaust with no cat. SCT tuner running a custom street tune. New FMIC with the extra tune on it. Head gaskets where done at 90k along with ARP studs. EGR cooler, The oil cooler was cleaned, New coolant tank. 1-new head and The cooling system was flushed at 90K. All done by the dealer along with some other items. Installed a bypass coolant filter at least 60k miles ago.
I have been having a no heat issue sometimes at idle this past winter and a mystery loss of coolant. I replaced the cap with a OEM one. I did a vacuum test on the coolant it held at 25 inches for well over a 1/2 hour. Pulled the egr valve it looked somewhat like tar inside not 100% dry. At startup it sometimes blows some white smoke and other times it's black smoke. I've had the scan gauge on for the last week to check my deltas.
Running 65mph the deltas stayed around 10 degrees diff.
Running 70mph the deltas stayed around 14-16 degrees diff.
Yesterday just running around rural roads 55mph and under the deltas stayed around 10 degrees diff.
I have not found a lower pressure gauge to do a coolant pressure test.
It does look as though it has burped the cap. Because of the deltas I'm thinking a plugged oil cooler my be the problem.
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I am having a heck of a time finding this coolant leak. It drips off the power steering pump. I replaced the upper radiator hose and the heater "y" hose that goes to the bottom of the Degas bottle. I recently replaced the lower radiator hose as well. So the truck runs normal. When the system is under pressure I do not see any leaks. But after the engine is completely cold it starts leaking a small puddle of coolant. Its appears to be coming from the power steering pump. But I am sure its something above or near it. This is on my 2005 Excursion with a 6.0. Can the water pump be going bad and leaking this direction. I would expect a water pump to leak straight down the middle of the engine. What to look for? The thermostat seal stays dry. but it has to be in that area. What is really messing with me is. When it is hot and pressured up It does not seem to leak. Only after it has been sitting for hours and cools off..........What the heck!
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I am in the middle of a several thousand mile road trip, and I am with family in Utah when this evening I noticed a puddle under my 6.0 Excursion.
Coolant leak? - YouTube
The fluid does not smell like typical coolant, but from the location of the drip, I cant think of it being anything else.
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Nothing to be alarmed about, I'm just letting y'all know I have a coolant leak on the front of the motor. It leaks about 8oz. Of fluid/week.
I have been through the radiator issues, 5 in all on my '08 and 1 on my '11 at 52,000 miles. This one is different, I'm pretty sure it's the water pump.
I'll give the official word as soon as I can get it diagnosed. I guess it's because I tow all the time, nothing real heavy, just everyday use. Truck is hardly ever on its own.
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Seen a coolant leak near the back of the block? I did an oil change and noticed coolant on the bell housing.
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I recently had an upper radiator hose bust and ever since I have been having a slight water leak. It appeared to be coming from between the layers of rubber on the new hose which I replaced twice since the incident. Both hoses had water seeping from the same location. This afternoon I plan on doing a pressure test on the cooling system to diagnose where the water may be coming from.
My question is could a loss of pressure cause larger than normal Oil and Water deltas? If I have to replace the radiator is there a particular manufacturer or type I should avoid? Should I try to get a factory replacement from Ford or would an Autoparts unit be sufficient? The original is still in the truck now with 286,000 miles on it.
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I just replaced the oil/egr cooler, stand pipes and dummy plugs along with all suggested upgrades, just filled with oil hooked up batteries and while filing with coolant it started gushing out from under the intake in front. I think I see an o-ring pushed out.. I hope I can lift the intake without removing the turbo!!!
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I have a O6 F250. Egr delete and a new oil cooler 20k ago. I have been dealing with missing coolant for about 6 months. A little here or there but it has gotten really bad the last few weeks. My last attempt was to replace the degas cap. Stopped the missing coolant for a 30 mile trip. Just to clarify it had gotten to the point I was adding one gallon per 20 miles. Needless to say I was thrilled. Next morning I came out to find coolant under the truck. Plastic Y under degass, so I replaced it. 25 miles and none missing. Next morning fluid under the truck. Now it's the egr hose.
Replaced it with a gates hose and new clamps. Fill it up with coolant go inside and its leaking in the same location. Its a pure pleasure to undertake. So I assume these leaks weren't previously leaking because the degass cap wasn't pressurizing the system. That being said the leak is on the oil cooler side of the egr hose. The snap lock fitting that was on the original housing spins around. Should that locking mechanism be removed before the hose is secured and clamped? This is the only thing I can come up with as the culprit. I have searched the information on the site but can't find any mention of it needing to be removed. The clamps are the right width and everything is seated.
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I have a 06 f250 that has a coolant leak in the front of the engine. It's was leaking about a month ago replaced the water pump it stopped. Then about 2 weeks later it started back up again. It only happens when the engine is cold. But once it warms up it starts leaking again. I am confused as all get out on this.
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Coolant seen leaking under passenger door it was running down frame rail looked under hood and seen coolant around the air filter cover . Tank was low 2012 cab chassis 33,000 miles
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