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Discussion Starter · #1 ·
I replaced my oil cooler since the deltas were reaching 30 degrees, as measured by Torque pro. It seemed pretty straight forward. I also deleted the EGR cooler while I was in there. Truck fired right up and I drove it for about 1600 miles with delta temps of 6-10 degrees. I monitor the temps constantly since I also put a filter on the coolant system and want to be sure that it isn't clogged.

The temps never went out of spec, but I noticed there was a little watery oil under the truck when it was parked. When I inspected it, the oil has found a way into the coolant and the top two inches in the degas bottle are black. Can the oil cooler fail to the point of allowing oil into the coolant without the temp spread showing a problem? Is this probably a busted cooler or a bad gasket? Could this be a head gasket issue that just coincidentally showed up after an unrelated repair?

I already have the cooler removed again and am awaiting on a new one, this time from Tousley Ford instead of a cheapo. Are there any installation pitfalls that can cause this problem that I need to avoid this time around?

For clarity, I installed the coolant filter in the place of a temporary filter I spliced into the line awaiting shipment. Point being, I was up close and paying attention to the coolant system for several weeks after the cooler install and would have noticed oil in it if the problem were present, so I'm confident whatever failed did so after the 1k mile mark. Thank you for any insight you may provide.
 

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If I had to touch the oil cooler on my 6.0, I'd never put back the stock configuration. It's so worth the $$$$ to go with the external air cooled oil cooler and filter that Bulletproof Diesel has; for most situations. I wouldn't use the stock configuration again if it were to fail. Money well spent, especially if you do the job yourself.

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Discussion Starter · #3 ·
I weighed that one out for a few days before making the choice. The 1500 plus cost is equivalent to 5 replacement stock coolers at Ford prices. The first lasted 130k miles without a filter, so the truck would need to run to a minimum of 650k miles before I break even on that cost difference. Of course, this math relies on proper parts and install, so I'm a little lower after the failed $120 cheapo investment, but lesson learned. At 150k mile intervals, I expect to need to clean the turbo anyway, so that is already 2/3s of the labor. Add a filter system and switch to ELC, which I did, and I think it's fair to assume I will need to make it to 800k miles to break even. I don't think I can stay entertained with any one vehicle that long.

I'm not trying to be contrary, but this is how I decided my course of action.
 
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I've heard that some of the off brand ones have gasket troubles. I guess you have confirmed it.
 

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Discussion Starter · #5 ·
I heard that too, but I couldn't figure out what gasket would allow oil into the coolant specifically. The tech articles I found say that the oil/coolant issue, along with the external leaking, are a signs of a blown cooler. Is there a way to test the oil cooler itself? I already started installing the new one, but I'll hold onto this one as a spare if it only needs better gaskets to be fully functional.
 

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I just replaced my OC this summer from the one replacement Ford put on about 5 or 6 years ago. Truck has 650,000 km on it and no coolant filter. I'm satisfied with OEM.
 

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Discussion Starter · #7 ·
Wow Phil. I hope we are all that lucky! Thanks.
 

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I too just ordered a coolant filter as my 6.0 still has a stock-style oil cooler...until the day comes that it pops or leaks. I do get the $$ decision, but it's the labor that get you on these jobs. I need as close to 100% reliability as possible as we go far afield off road a lot. It's worth the peace of mine to me...again, the decision has a lot to do with me not paying someone else to install it. Same goes with an upgraded aftermarket EGR cooler, if it starts leaking or gets clogged with carbon deposits, I'd upgrade for reliability.

Any computer codes thrown with the EGR delete? Does your area require a smog check? Thx.





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Discussion Starter · #9 ·
Thanks Michael that makes good sense. I am getting the code for the lack of flow through the EGR, but there is no smog test where I'm located. I take mine in and out of the desert, but rarely on extended excursions and then usually not alone. If I were in your situation, by the sound of it, I'd opt for the maintenance free version as well. Thanks for weighing in, I get caught up in trying to save money and sometimes don't fully consider the other issues, like piece of mind in the middle of nowhere.
 
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