6.0L Power Stroke Engine and DrivetrainDiscussion of the 6.0L Power Stroke diesel engine and drivetrain in the 2003-Up Super-Duties and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 6.0L Power Stroke engine.
Well, I finally had my first major issue with my 04 F350 4x4 Crew. I have what looks like tan, thick paint in my degass bottle. Needless to say the oil cooler pooped the bed. Dealer is quoting approximately $1200, 95,000 total miles so under 100K miles but 5 months out of 5 year warranty. Does that sound about right. He is also stating a 2 to 3 day job. Sound about right?
Thanks.
PS. I contacted Ford Customer Service to see if they'd cut me a break on the repair since I'm so close to running out of warranty.
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2004 F350 Crew XLT 4x4 long box, SRW, 3.73 Gears
Bone Stock
Good Luck with Ford Customer Service... I was 10,000 KMS under my 160K warranty and 1 month out and I couldn't get them to pay for squat when I had an injector fail... "There is nothing we can do" they kept saying... I don't really think I am an unreasonable person by asking that they at least pay part of the repair... Especially since they have been having issues with injectors in these trucks to begin with...
I don't know anyhting about the oil cooler so good luck with that...
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2003 F350, 6.0L Lariat 210,000kms, Stock except for the Pioneer in dash Nav unit with Back-up Camera...
Well, I finally had my first major issue with my 04 F350 4x4 Crew. I have what looks like tan, thick paint in my degass bottle. Needless to say the oil cooler pooped the bed. Dealer is quoting approximately $1200, 95,000 total miles so under 100K miles but 5 months out of 5 year warranty. Does that sound about right. He is also stating a 2 to 3 day job. Sound about right?
Thanks.
PS. I contacted Ford Customer Service to see if they'd cut me a break on the repair since I'm so close to running out of warranty.
I had about a week left on my 5 year/100K mile warranty when my egr/oil coolers went out, dealer also replaced egr valve and flushed the cooling system and changed oil all under warranty ($100 ded) they had it three days, he told me appox $2700 job, I have seen others stating on here approx $2300. Look into a coolant filter after its fixed, something we should have done along time ago, good luck with the truck and the warranty claim!!
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2004 F-250 Crew Cab XLT, Auto, Short Bed, Arizona Beige, Fx4/Camper Pkg., 265's, Built 4/23/04, Delivered 4/27/04
Retrax Bed Cover,Crimestopper Alarm/ Keyless Entry/ Remote Start/ Skweeker Idle Up Mod/ Marinco Built in Heater Plug/ Dieselsite coolant filter My Truck
Make sure that they replace the EGR cooler too, otherwise you're going to have problems again, and it's going to cost you more money,,,,,,,again.
Some stealerships like to do that.
__________________ SFC Fred Lynes
2004 F-350 CC DRW LB FX4 4x4
Oxford White/Arizona Beige
King Ranch Package
Herrin Hauler Package
5R110 Torqshift
4.10:1 Dana 80 Trac-Lok
9,200lbs GVW
Reman'd 6.0L @43,956 miles
Reman'd Turbo @54,814 miles Wishin' I still had my '05 2500HD CTD Ram
this job is a pain. they gotta replace all the hoses, the oil cooler, most shops will replace the egr cooler and send the radiator out to be cleaned. then you gotta run simple green through the cooling system to clean as much out as you can. then they'll run fords cooling system flush through it a couple times. you quote sounds actually pretty good seeing as this is a big job. but you said your 5 months till you go out of warranty and this should be covered.
this job is a pain. they gotta replace all the hoses, the oil cooler, most shops will replace the egr cooler and send the radiator out to be cleaned. then you gotta run simple green through the cooling system to clean as much out as you can. then they'll run fords cooling system flush through it a couple times. you quote sounds actually pretty good seeing as this is a big job. but you said your 5 months till you go out of warranty and this should be covered.
Actually, I'm 5 months OUT of warranty. I could tell by the gunk in the degass bottle that it would take some time to clean this out of everything. They told me there is a kit, around 300 bucks that would permanently fix this issue whereas in the past they were fixing it and it would happen again. Considering how much I tow with this truck, and I'm ashamed to admit I was hauling 30,000lbs gross weight (truck, grain cart and oats) and regularly tow 14,000 lbs I can't complain about the truck. Sounds like I'm getting a fair price and that's all I can ask for.
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2004 F350 Crew XLT 4x4 long box, SRW, 3.73 Gears
Bone Stock
Assuming it's just the EGR cooler, they should replace the EGR cooler, oil cooler and degas bottle. Cost = $2200 here in north Alabama at the local dealer. About a 2 day job.
Second the comment to adding a coolant filter. In all likelihood, this would have prevented the EGR cooler failure in the first place, or at least mitigated it greatly.
I have never heard of other engines having these problems. Why does the 6.0 have so much casting sand left in it?
__________________ SFC Fred Lynes
2004 F-350 CC DRW LB FX4 4x4
Oxford White/Arizona Beige
King Ranch Package
Herrin Hauler Package
5R110 Torqshift
4.10:1 Dana 80 Trac-Lok
9,200lbs GVW
Reman'd 6.0L @43,956 miles
Reman'd Turbo @54,814 miles Wishin' I still had my '05 2500HD CTD Ram
I don't think the 6.0 has any more casting sand than any other engine, I've seen pretty much the same stuff in about the same amount in the first coolant filters for the 7.3 PSD and the 5.9 Dodge gasser motors.
What's different about the 6.0 is it's asymmetric liquid-to-liquid oil cooler, with engine coolant on one side and engine oil on the other side. Guess which side has the smaller passages? Yep, you guessed it, the coolant side.
The oil cooler coolant side is in series and comes before the EGR cooler in coolant flow. Therefore, when the oil cooler coolant passages plug up, it reduces and finally stops coolant flow to the EGR cooler. After enough running time and especially when towing or under heavy load, the EGR cooler fails, sending exhaust gases into the coolant system, end result: "puking" out the degas bottle.
These symptoms look just like failed head gaskets, hence early 6.0 failures were oftentimes misdiagnosed as head gasket failures; this is not to say that the 6.0 doesn't have head problems, it does and the number and size and use of head bolts instead of studs is the culprit.
I don't think the 6.0 has any more casting sand than any other engine, I've seen pretty much the same stuff in about the same amount in the first coolant filters for the 7.3 PSD and the 5.9 Dodge gasser motors.
What's different about the 6.0 is it's asymmetric liquid-to-liquid oil cooler, with engine coolant on one side and engine oil on the other side. Guess which side has the smaller passages? Yep, you guessed it, the coolant side.
The oil cooler coolant side is in series and comes before the EGR cooler in coolant flow. Therefore, when the oil cooler coolant passages plug up, it reduces and finally stops coolant flow to the EGR cooler. After enough running time and especially when towing or under heavy load, the EGR cooler fails, sending exhaust gases into the coolant system, end result: "puking" out the degas bottle.
These symptoms look just like failed head gaskets, hence early 6.0 failures were oftentimes misdiagnosed as head gasket failures; this is not to say that the 6.0 doesn't have head problems, it does and the number and size and use of head bolts instead of studs is the culprit.
Hope this helps.
Al
Yeah, I knew that Al, but it's always good to get a refresher. It would seem that relocating the oil to an external location would be a good idea. I see that there are a couple of companies that make the external oil coolers, but I have yet to talk to someone who has actually put the product on their truck.
__________________ SFC Fred Lynes
2004 F-350 CC DRW LB FX4 4x4
Oxford White/Arizona Beige
King Ranch Package
Herrin Hauler Package
5R110 Torqshift
4.10:1 Dana 80 Trac-Lok
9,200lbs GVW
Reman'd 6.0L @43,956 miles
Reman'd Turbo @54,814 miles Wishin' I still had my '05 2500HD CTD Ram
I don't think the 6.0 has any more casting sand than any other engine, I've seen pretty much the same stuff in about the same amount in the first coolant filters for the 7.3 PSD and the 5.9 Dodge gasser motors.
I agree with Al. It isn't the amount of casting sand. The problem is the design. Whoever thought to put an oil cooler with too small of passages that can easily clog, directly between the water pump and the EGR cooler, should be forced to repair everyone of them that breaks.
__________________ 2003 Toreador Red/Arizona Beige CC, DRW, Lariat, FX4, 6.0 PSD, Torqshift, born early Feb. 03, AIC, MBRP turbo-back exhaust, Tuning by Tony Wildman (Total Diesel Performance), ARP studs & some "other" work done by River City Diesel, AFE PG7, Fumoto valve, B&W hitch, Di-Pricol gauges, Voyager brake controller, DIESELSITE Coolant filter, Timbrens, Rancho RSXs, Michelin XPS Traction's, a whole bunch of "bling", Connex 4300hp, JL Audio 275w amp w/ 12" sub, Alpine door and rear seat speakers.
I agree with Al. It isn't the amount of casting sand. The problem is the design. Whoever thought to put an oil cooler with too small of passages that can easily clog, directly between the water pump and the EGR cooler, should be forced to repair everyone of them that breaks.
Agreed.
__________________ SFC Fred Lynes
2004 F-350 CC DRW LB FX4 4x4
Oxford White/Arizona Beige
King Ranch Package
Herrin Hauler Package
5R110 Torqshift
4.10:1 Dana 80 Trac-Lok
9,200lbs GVW
Reman'd 6.0L @43,956 miles
Reman'd Turbo @54,814 miles Wishin' I still had my '05 2500HD CTD Ram
Well, you boys were right. The Ford Superduty Team has decided not to "participate" in this repair. Total bill was $1822. Oh well, at least I have it back and knock on wood that will be the last major repair bill I'll have. I guess I need to stop pulling 29,000lbs gross when I'm using it on the farm before I fry something else. BTW, I don't recommend pulling that much total weight, truck, 550 bushel grain cart filled with oats, it pulls great, stopping, not so much
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2004 F350 Crew XLT 4x4 long box, SRW, 3.73 Gears
Bone Stock
What oil cooler is this post about? Engine or auto transmission and where is it located? I see some sort of oil cooler below the Radiator in front. 2000 F250 SD 7.3 stick
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F-250 2000 4x2 SC SD Long Bed, 6-speed, American Racing 'Kong Wheels, Glasstite Camper Shell, Tow 27' 1970 Vintage Airstream
What oil cooler is this post about? Engine or auto transmission and where is it located? I see some sort of oil cooler below the Radiator in front. 2000 F250 SD 7.3 stick
The engine oil cooler. It is in the valley on the front of the motor below the oil filter.
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2007 F350 XLT 4x4 SC 6.0 PSD No Mods
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2003 Toreador Red/Arizona Beige CC, DRW, Lariat, FX4, 6.0 PSD, Torqshift, born early Feb. 03, AIC, MBRP turbo-back exhaust, Tuning by Tony Wildman (Total Diesel Performance), ARP studs & some "other" work done by River City Diesel, AFE PG7, Fumoto valve, B&W hitch, Di-Pricol gauges, Voyager brake controller, DIESELSITE Coolant filter, Timbrens, Rancho RSXs, Michelin XPS Traction's, a whole bunch of "bling", Connex 4300hp, JL Audio 275w amp w/ 12" sub, Alpine door and rear seat speakers. 
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