Finished the oil/egr cooler swap

[3gees]

I just wanted to post this for the people that are considering doing the swap by themselves. It took me a week of 3-4 hours a night after work to complete the swap. The kits came with all the o-rings and gaskets that were needed to complete the task, I didn't have to run out in the middle of the project to try and find any parts. The project was tedious but not difficult. Everyhting came apart without struggle and went back together the same way. I am glad I took on this challange and saved myself a few thousand bucks. Here is a list of what I changed and the price:

Oil cooler = $475 + sh
Egr Cooler = $330 +sh
Degas Bottle = $60.28
Thermostat = $30 something - cant remember
Coolant Filter = $160 with valves, extra filter and shipping
4 gallons FORD Gold coolant = $48
Oil change = $55
Torque wrench = $100

Rough total:$1260

[DieselDoctor22]

hey 3gees,

if you dont mind me asking why did you change out all these components did you have problems before. What kind of coolant filter setup did you get.

[3gees]

dieseldoctor22,
I had problems with a clogged oil cooler so while I had it apart I did the egr cooler too. As far as the coolant filter I bought it from "Dieselsite.com" as recommended by others on this forum.

[thebozman]

Why did you choose not to do the EGR cooler delete?

[boulder]

3gees,
do you have any links or instructions on how to do this change out? I have the preliminary signs that something is up. There appears to be the puffing sound and sings of coolant coming out of the degas bottle. I just had the system flushed, but it is still making the puffing sound and has the signs of leaking around the degass bottle cap.

[bismic]

Way to go 3gees!

[theboman]

Did your oil cooler blow up? Mine did! The ERG cooler is stopped up. When this happens Ford dealers flush the entire cooling system with 3 gallons of Simple Green (I assume to get rid of the oil thru the system and clean the heater coil of all the oil that went thru the cooling system. They also send the radiator out to a radiator shop to boil it clean too.

Geez, I'm looking $3600+ as of last Friday, and I told them go ahead replace the fuel filters.

[3gees]

My oil cooler didn't blow up or even leak in to the coolant. The only symptoms i had was venting coolant out of the degas bottle, but only when towing. At first, i thought head gaskets, but then i did some more research on this site and read about the clogging of the oil cooler. This seem to fit my situation better than head gaskets for these reasons: (1) I towed the TT in October 08 with no issues with the coolant (2) During the winter i only used the truck maybe once a week or two weeks (3) I towed the TT in April 09 and had the coolant issues. I am not a mechanic by trade but it seemed to me that the head gaskets/bolts would not go bad from October to April with limited use, but a clogged oil cooler made sense due to the fact of that muddy coolant just sitting in the engine for the most part of the winter. I hate paying labor for somthing I think I can do myself so I went for it and so far so good.

[3gees]

Originally Posted by boulder

3gees,
do you have any links or instructions on how to do this change out?

I do not have instructions. I identified the location of the oil cooler and just started removing stuff until i revealed the cooler. I refered to the 6.0 bible for some helpful pics and definitely the torque specs and bolt tightening sequences on the intake manifold. I just took my time and labeled every plug or bolt that i removed.

[boulder]

Thanks for the response 3gees. I sent you a PM, but for others benefit could you tell me where you ordered your parts from? specifically the 2 coolers. Also did you have to remove the intake manifold to remove the EGR cooler and then get to the oil cooler? I am pretty sure that the turbo has to come off but you may be able to confirm that as well.

thanks again.

[3gees]

I bought the oil and egr coolers from Welcome to PartsCentralUSA Check your pm for the rest. Hope it helps!

[3gees]

Update: I took the TT for a trip for the first time since replacing the egr/oil cooler and everything seemed to be ok. The trip was a 200 mile trip from southern NJ to CherryStone CG in VA. There was a lot of stop and go with traffic lights (Rt 13 if your familiar) and all seemed to be ok. I was more nervous about the trip because I did all the work myself and this was the first time I have done such invasive work on a newer vehicle. So far so good!! I just wanted to put that out there.

Thanks for all the help and guidance from this site.

[Albin]

Do you still have the old oil cooler as it came off the engine? Anyway to take pics of it?

Here's what I did to a friend's oil cooler and what was plugging it up.

Al

[NU2Diesel2006]

Albin,

that is pretty gunked up. What the h**l is that stuff?

[rsd]

What years do you have to worry about casting sand in the coolers?