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It could very well be blown head gaskets, but there is a great chance that it is your EGR Cooler/Engine Oil Cooler that is causing this problem. Here is how it works:
The coolant comes out of the radiator at about 160°F, give or take. It then flows to the water pump. A portion of the coolant then goes into the EOC where it flows through tight passageways adjacent to hot engine oil. While this EOC has coolant and engine oil in it, the two fluids flow next to each other within the cooler but do not mix.
The problem starts with the tight pathways inside the EOC. The pathways for the coolant are so small and clogged with fins (to enable heat transfer) that it is possible for the silicates and sand found within the coolant to become lodged in the cooler. This creates a blockage and hinders the flow of coolant through your EOC.
The coolant flows through and emerges from the EOC at about 200°F before flowing into the EGR cooler. Within the EGR cooler, the coolant is trying to cool the hot exhaust gasses that are moving nearby in the adjacent heat tubes.
The problem arises when the EOC becomes restricted. As the pathways for the coolant within the EOC become plugged with sand and silicates, the coolant can no longer flow through the EOC. So instead of getting, as an example only, 1 gallon of coolant per minute through the cooler, you might now only get ˝ of that amount. This means that the EGR cooler - instead of getting 1 gallon per minute to keep it cool - is also only getting ˝ a gallon per minute.
To put it nicely, the Ford EGR cooler is “sensitive” to the proper flow of coolant. If it doesn’t get enough coolant, then it is not going to stay cool. This is what is occurring (most likely) in your truck now. As the coolant moves slowly through your EGR cooler, it is being exposed to hot exhaust gasses. The extreme heat from the exhaust is too much for too little coolant and causes the coolant to boil – which shows up as “puking” of coolant from your overflow bottle.
That being said, do you have an EGR cooler on your truck?
Gene
__________________
ASE Master Tech
Diesel Shop Owner
2005 F350 4x4 Crew Cab 6.0L
Upgraded EGR Cooler
BulletProofDiesel Engine Oil Cooler
http://www.bulletproofdiesel.com
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