Excursion 4WD V8-6.0L DSL Turbo VIN P (2004)
Cylinder Head Gasket: Customer Interest
Cooling System - Overheating/Coolant Loss
TSB 09-8-3
05/04/09
COOLANT LOSS - 6.0L
FORD:
2003-2005 Excursion
2003-2007 F-Super Duty
2004-2009 E-Series
This article supersedes TSB 08-11-3 to update the Service Procedure, which includes the release of a new Oil Cooler Service Kit. The Oil Cooler
Service Kit includes a serviceable heat exchanger, which is to be used to service a restricted oil cooler. Replacement of the entire Oil Cooler assembly
due to flow restriction is no longer necessary.
ISSUE
Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2009 E-Series vehicles, all equipped with a 6.0L engine, may exhibit:
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Coolant venting from the degas bottle cap
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Internal engine coolant leak (possibly resulting in a hydro-locked engine)
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White smoke from tail pipe
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Coolant loss
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Lacks power due to overheating
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No cabin heat
The conditions typically occur when operating the vehicle under a load such as trailer towing, uphill driving, or both.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Following the Service Procedure steps will aid in isolating the source of the coolant leak condition by testing and repairing as necessary the following:
degas bottle and pressure cap integrity, exhaust gas recirculation (EGR) cooler for internal leaks and the oil cooler for coolant flow restrictions. All
vehicles will be required to have the cooling system flushed with Motorcraft(R) Engine Cooling System Iron Cleaner. For vehicles that are diagnosed to
have leaking head gaskets, you will be required to test the turbocharger for causing an over-boost condition, which may be the cause of the head gasket
failure.
NOTE
PLEASE REFER TO THE WARRANTY AND POLICY MANUAL, SECTION 3, FOR WARRANTY IMPLICATIONS OF REPAIRS RELATED
TO VEHICLE MODIFICATIONS.
NOTE
A NEW OIL COOLER SERVICE KIT, WHICH INCLUDES A SERVICEABLE HEAT EXCHANGER, IS TO BE USED TO SERVICE A
RESTRICTED OIL COOLER. REPLACEMENT OF THE ENTIRE OIL COOLER ASSEMBLY DUE TO FLOW RESTRICTION IS NO
LONGER NECESSARY.
Prior to making any repairs, verify the coolant level is not overfull. The correct cold coolant fill level is at the MIN line of the degas bottle cold.
Overfilled coolant levels will cause coolant to vent from the degas bottle cap.
Complete All Steps In Order As Outlined (Steps 1-4 Must Be Performed On A Cold Engine)
