Oil Leak from intercooler hose - Diesel Forum - TheDieselStop.com
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99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the 99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks 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 7.3L Power Stroke engine.

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Old 02-27-2009, 08:47 PM   #1 (permalink)
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Oil Leak from intercooler hose

I have oil leaking from the intercooler hose where it connects to the intercooler on the passenger side. What is my problem and how do I correct? Thanks.
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Old 02-27-2009, 09:56 PM   #2 (permalink)
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oil is intorduced to the intercooler system via your ccv(crankcase vent)so oil is not circulated through(like a oil cooler line would)the intercooler system.but because the ccv system feeds into this oil accumulates in variuos places.if you have a leak i would suspest you either have a loose boot or a boot with a hole in it.you should be able to purchase new boots and install them to correct the problem.but verify it is coming from the boot.not a cracked line or the intercooler itself.
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knock on wood....
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4r100 1-2 2-3 3-4sonnax accumulator valves,.427 sonnax line pressure mod valve
4.125"yes thats 4 1/8" diy tymar intake(size matters...lol)
AIH delete,ccv delete,zoodad mod,
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Old 02-28-2009, 03:41 PM   #3 (permalink)
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I disagree that new boots are the answer. If you have excess oil in the system (as I had) it will get through - even new boots. I installed a CCV catch can and that solved most of the problem - at least until the residual oil leaked out of the IC hoses.
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Old 03-01-2009, 12:14 AM   #4 (permalink)
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i didnt say new boots will fix it i was explaining that oil builds up in the intercooler system,but being oil is petroleum it will soften rubber boots and potentialy lead to failure.
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2002 f250 lariat 7.3 220k(motor has 190k)
original 4r100 tranny....220k and counting
knock on wood....
red elc good for 150k
4r100 1-2 2-3 3-4sonnax accumulator valves,.427 sonnax line pressure mod valve
4.125"yes thats 4 1/8" diy tymar intake(size matters...lol)
AIH delete,ccv delete,zoodad mod,
4" exhaust no muff
built my own leafs for 4.0 of lift!!!!!!
18" xd bronze revolvers with 325 nittos to wrap them
isspro pyro and boost guages on pillar mount....
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Old 03-01-2009, 01:01 AM   #5 (permalink)
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If you need new boots go here Diesel Power Products | OH150 | 99-03 Ford Powerstroke 7.3L Hose Kit

If the boots are not soft or spongy from the oil, wash them with soap and water use Dawn dish water soap. Dry them off good. Spray the metal tube ends and the turbo ends with hair spray and slip the boots back on, DO NOT over tighten the clamps, tighten just so they do not squeeze into the boot, the hair spray will sort of glue them.

The oil in the intercooler tubes is natural, lots of mods have been tried .
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Old 03-01-2009, 09:07 AM   #6 (permalink)
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Quote:
Originally Posted by tattoocharlie View Post
i didnt say new boots will fix it i was explaining that oil builds up in the intercooler system,but being oil is petroleum it will soften rubber boots and potentialy lead to failure.
Actually, what you said was, "you should be able to purchase new boots and install them to correct the problem." To me that sounded like new boots are the answer, sorry if I misinterpreted. In my limited experience (just with my own truck - and almost 10 yrs of watching and reading on this site), new boots certainly was NOT the answer.

You can see an old post of mine Oil in valley - from intake boots? after CCV mod.
I never followed up with the conclusion to this issue, but it was indeed residual oil in the intercooler (at least I presume), b/c it eventually stopped leaking from the boots.

These are the boots I used on my truck - 1999.5-2003 7.3L DIESELSITE Engine Boot Kit (After 12/1/98)

So anyhow, if you have oil coming from the boots, my advice to do the CCV mod. That said, it seems some trucks simply have MORE oil going through those boots than others. For many people simply removing the boots, cleaning them inside and out really well and reinstalling is good enough for another 50k. For me cleaning them worked for a few thousand miles. For me installing new aftermarket "oil proof" boots was good for a little longer. I guess my truck has enough blow by that the CCV mod was only answer.

I suspect had I done the CCV mod first, I would have been able to save the money on aftermarket boots and kept the originals. I fell for the advice that new boots would solve the problem. My advice is if you have a lot of oil coming from the boots you should do the following:

1. Remove and thouroughly clean the IC boots, then watch for oil.

2. IF in a few months the oil has returned, do the CCV mod.

(All this assumes you do not have an oil leak from some other source!

Good luck.
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Jack

Last edited by jgarden; 03-01-2009 at 09:11 AM.
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Old 03-01-2009, 10:25 PM   #7 (permalink)
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Quote:
Originally Posted by jgarden View Post
Actually, what you said was, "you should be able to purchase new boots and install them to correct the problem." To me that sounded like new boots are the answer, sorry if I misinterpreted. In my limited experience (just with my own truck - and almost 10 yrs of watching and reading on this site), new boots certainly was NOT the answer.

You can see an old post of mine Oil in valley - from intake boots? after CCV mod.
I never followed up with the conclusion to this issue, but it was indeed residual oil in the intercooler (at least I presume), b/c it eventually stopped leaking from the boots.

These are the boots I used on my truck - 1999.5-2003 7.3L DIESELSITE Engine Boot Kit (After 12/1/98)

So anyhow, if you have oil coming from the boots, my advice to do the CCV mod. That said, it seems some trucks simply have MORE oil going through those boots than others. For many people simply removing the boots, cleaning them inside and out really well and reinstalling is good enough for another 50k. For me cleaning them worked for a few thousand miles. For me installing new aftermarket "oil proof" boots was good for a little longer. I guess my truck has enough blow by that the CCV mod was only answer.

I suspect had I done the CCV mod first, I would have been able to save the money on aftermarket boots and kept the originals. I fell for the advice that new boots would solve the problem. My advice is if you have a lot of oil coming from the boots you should do the following:

1. Remove and thouroughly clean the IC boots, then watch for oil.

2. IF in a few months the oil has returned, do the CCV mod.

(All this assumes you do not have an oil leak from some other source!

Good luck.
it actually says if you have a loose boot or one with a HOLE in it,you can correct it with new boots.i was just saying if you have a damaged boot its an easy fix.
__________________
2002 f250 lariat 7.3 220k(motor has 190k)
original 4r100 tranny....220k and counting
knock on wood....
red elc good for 150k
4r100 1-2 2-3 3-4sonnax accumulator valves,.427 sonnax line pressure mod valve
4.125"yes thats 4 1/8" diy tymar intake(size matters...lol)
AIH delete,ccv delete,zoodad mod,
4" exhaust no muff
built my own leafs for 4.0 of lift!!!!!!
18" xd bronze revolvers with 325 nittos to wrap them
isspro pyro and boost guages on pillar mount....
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Old 03-02-2009, 05:24 PM   #8 (permalink)
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Mine intercooler boots were leaking and this worked for me - remove the boots and clean them and the surfaces they mount real well. Spray the contacting surfaces with hair spray - this will give it a tacky surface to keep it from leaking, but won't prevent you from removing it later. Reassemble and you're done. Mine haven't leaked since.
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