F 250 2WD Super Duty V8-6.0L DSL Turbo VIN P (2004)
Intercooler Duct: Customer Interest
Diesel Engine - Oil Leak/Low Power/Low Boost Performance
TSB 04-20-9
10/18/04
LOW POWER - COLD SIDE CHARGE AIR COOLER
(CAC) DISCONNECTED - OIL LEAK AT COLD SIDE
CAC CONNECTIONS - 6.0L ENGINE - VEHICLES
BUILT 12/15/2003 THROUGH 4/1/2004
FORD:
2004 Excursion, F-Super Duty
ISSUE
Some 6.0L equipped vehicles built 12/15/2003 through 4/1/2004 may exhibit an oil leak from the cold side charge air cooler (CAC) connections, or low
power/low boost performance due to the plastic charge air cooler duct becoming disconnected (blowing off).
ACTION
Replace the CAC duct with a revised part that includes a T-Bolt Clamp. DO NOT replace the plastic CAC tubes with prior level aluminized tube and
black silicone hoses. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
OIL FOUND IN 6.OL CAC SYSTEM MAY BE GREATER THAN AMOUNTS PREVIOUSLY FOUND IN THE 7.3L ENGINE, DUE TO
HIGHER BOOST LEVELS. A RESTRICTED AIR FILTER CAN ALSO CONTRIBUTE TO GREATER AMOUNTS OF OIL IN THE CAC
SYSTEM. ENGINE OPERATION WITH A RESTRICTED AIR FILTER INCREASES THE AIR FLOW THROUGH THE OIL SEPARATOR,
LEADING TO GREATLY INCREASED OIL IN THE BLOW-BY GAS AND RESULTING IN OIL PUDDLING IN THE DUCTS. PROPER AIR
FILTER MAINTENANCE IS IMPORTANT. DUSTINESS AROUND THE CAC DUCT CONNECTIONS IS CONSIDERED NORMAL.
1.
Clean both connecting ports and the inside surface on both ends of the duct with Motorcraft Brake Cleaner (PM-4).
2.
After reinstalling duct on both ports, position the internal bead of the duct into the groove in the engine elbow and torque the clamp to 12 N.m
(106 lb-in).
3.
Push the other end squarely and fully onto the CAC port and torque the clamp to 12 N.m (106 lb-in).
CAUTION
DO NOT OVER-TORQUE THE CLAMP.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION
DESCRIPTION
TIME
042009A
Replace The Charge Air
0.4 Hr.
Cooler Duct (Includes Time
To Remove And Install Air
Filter)
DEALER CODING
CONDITION
BASIC PART NO.
CODE
6C646
42
