coolant loss at cold temperatures - Diesel Forum

ere1976 · 12-13-2006, 04:32 PM

I drive a 2003 Ford F350 Diesel and I have been losing coolant overnight when the temperature is < 40 degrees. the leak seems to be in the back of the enging behind the turbo charger. I know this sounds weird but it started when I drove to Colorado and there was low temperatures every night. During the trip I had to add about a gallon of coolant every morning but it did not lose anything during the day when I drove it well over 100 miles daily. I took the truck to a Ford dealership in Colorado but they just charged me $90 to tell me that thier best guess was that it was the EGR coolant valve but they would have to remove the turbo charger to check it out and that would cost > $700. I decided to wait until I returned home to Texas and now it doesn't leak as much, but it still leaks. I guess its because it is not that cold here. I think it must have something to do with the overnight temperature because it does not lose any coolant when it is not so cold. I took it to my regular mechanic and he couldn't find where the leak was coming from when he crawled underneath. He also told me he would remove the turbine and look more thoroughly but he would have to charge me for it. Has anybody else had this problem or any suggestions?

GregH · 12-14-2006, 08:54 AM

I've got $5 on the orange coolant hose on the EGR cooler. They tend to leak at low temperatures and seal back off at higher temps.

Turbo, intake and EGR cooler removal is usually required to repair the concern. However, there is a much quicker method.

In fact, I've got an idea for an even faster method - on the order of about 30-45 minutes.... However, I haven't had an opportunity to see if it would work.

Anyway, I'll bet it's that little orange hose... Look for coolant traces around it next time you've got the hood up...

Black05 · 12-14-2006, 10:06 AM

Greg -- Are you going to try it first, or let us know what your idea is so someone else can try it? You've got our attention!

a3upper · 12-14-2006, 12:08 PM

EGR Cooler hose - New one is revised and blue in color not orange. Been there done that. Good Luck!

A3upper

GregH · 12-14-2006, 01:56 PM

Well, the first method is, of course, the shop manual's. Remove intake, turbo, EGR cooler...

Second method is to remove the turbo and pedestal, slide the orange hose off and bend the EGR coolant tube over a bit to clear the oil cooler, then replace the hose.

Third method - which I haven't tried - is to slide the orange hose back, remove the two Torx screws on the oil cooler cover (the small oval cover), remove the cover and outlet fitting, then slide the orange hose out without bending the EGR coolant tube. Might work, might not. I'm thinking about it without actually looking at a 6.0L, so I don't know if any additional components will need to be removed for access, or if there is enough room with the cover and outlet fitting removed....

ere1976 · 12-14-2006, 06:16 PM

thanks for the tip on the EGR coolant hose. is the conventional way of removing the intake & turbine something that can be done by the average home mechanic? I never used to have trouble fixing my old 1964 Chevy but now it seems like all trucks have too many electronics for me. I am a general do it yourselfer but I don't want to start something I can't finish. On another topic, does anybody know where I can get a repair manual for this truck? I asked at different auto repair stores but it seems like Hayne's and Chilton's don't make one for this truck yet.

GregH · 12-15-2006, 04:50 PM

I would consider doing this repair in my driveway. But, I've been there more than a few times. There are certain things that you need to be careful of - like the possibility of seized bolts in the turbo, the likelyhood of the left rear intake manifold stud turning before the nut (that retains a ground lug) turns, etc. I've got a few particular tools that I use on this job - an old 10mm craftsman open end that I shaved down to address the intake stud issue, and a 10mm 6pt. matco short pattern box wrench for the rear turbo bolt.

This job is pretty easy and straightforward, but it can really turn to crap fast... Access to air power and a wide assortment of tools, as well as the knowledge to get yourself out of a jam are all very valuable...

muffler · 12-15-2006, 05:57 PM

look at my reply on coolant just above your post.
My leak was a EGR adaptor , it had a flattened O ring

Steve

tperk100 · 01-07-2011, 04:49 PM

I am reviving this old post because I need to replace a leaking orange hose. Can someone Verify / Update / Post etc the procedure for doing this in 20 minutes?

Thanks

04KingRanch6.0 · 01-11-2011, 10:55 PM

Does an EGR delete kit eliminate this leak and all parts associated with it? I noticed an unexplained leak this morning which is probably this problem.