We are working on a 04 f-350 with a build date of late 03.

We are replacing the oil cooler and egr cooler and screen this weekend and i would like some more details before we start, can any body help with links for step by step instructions or shortcuts and general help.

Thank you !

 

Look in tech folder

 

I had the same things done to my 04 250 with the 03 engine. Oil cooler was plugged with what appears to be casting sand. Egr cooler was intact but put in a new one anyway. One thing that I did do was to have a ss freeze plug welded into the exhaust input end of the egr cooler. No more exhaust flow into the system now. So far excellent results with no codes and great performance. Also the system looks and act perfectly normal re EPA insp. I have also added a coolant filter to my system. Work done at 91k now 96k and all well. Good luck.

 

Just walked in the house from doing my oil cooler 5 inutes ago.
Tip1 get a freeze plug welded into the exhaust end of that new cooler.
tip2, Don't be lazy ,,Pull the connector off the first two injectors on each side.
tip3 clean the valley AFTER you pull the turbo but BEFORE you pull the oil cooler, it could save your IPR.
be sure to protect the turbo drain hole in the HPOP.

 

<TABLE style="WIDTH: 698pt; BORDER-COLLAPSE: collapse" border=0 cellSpacing=0 cellPadding=0 width=931 x:str><COLGROUP><COL style="WIDTH: 698pt; mso-width-source: userset; mso-width-alt: 32896" width=931><TBODY><TR style="HEIGHT: 21.1pt; mso-height-source: userset" height=28><TD style="BORDER-BOTTOM: #d4d0c8; BORDER-LEFT: #d4d0c8; BACKGROUND-COLOR: fuchsia; WIDTH: 698pt; HEIGHT: 21.1pt; BORDER-TOP: #d4d0c8; BORDER-RIGHT: #d4d0c8" class=xl24 height=28 width=931>Oil Cooler and Coolant info and pics:</TD></TR><TR style="HEIGHT: 12.9pt" height=17><TD style="BORDER-BOTTOM: #d4d0c8; BORDER-LEFT: #d4d0c8; BACKGROUND-COLOR: fuchsia; WIDTH: 698pt; HEIGHT: 12.9pt; BORDER-TOP: #d4d0c8; BORDER-RIGHT: #d4d0c8" class=xl26 height=17 width=931>http://www.forddoctorsdts.com/articles/article-09-01.php</TD></TR><TR style="HEIGHT: 13.6pt" height=18><TD style="BORDER-BOTTOM: #d4d0c8; BORDER-LEFT: #d4d0c8; BACKGROUND-COLOR: fuchsia; WIDTH: 698pt; HEIGHT: 13.6pt; BORDER-TOP: #d4d0c8; BORDER-RIGHT: #d4d0c8" class=xl25 height=18 width=931>OIL COOLER REPLACEMENT</TD></TR><TR style="HEIGHT: 67.95pt" height=91><TD style="BORDER-BOTTOM: windowtext 0.5pt solid; BORDER-LEFT: windowtext 0.5pt solid; BACKGROUND-COLOR: fuchsia; WIDTH: 698pt; HEIGHT: 67.95pt; BORDER-TOP: windowtext 0.5pt solid; BORDER-RIGHT: windowtext 0.5pt solid" class=xl27 height=91 width=931>The oil cooler kit has all the gaskets needed but you should get the intake set and the screen under the oil pump. The intake gaskets are re-useable, but get new ones just in case. Make sure you clean the area real well around oil cooler before you remove it. Remove the old oil in the cavity under the oil cooler and once the screen is replaced make sure you add a quart of fresh oil before installing the oil cooler. Places a few rags behind the oil cooler where the turbo pedastle would be before you pull the oil cooler to catch the oil as it runs out. Also change the oil and filter and know it will take awhile to crank before it starts.</TD></TR><TR style="HEIGHT: 13.6pt" height=18><TD style="BORDER-BOTTOM: windowtext 0.5pt solid; BORDER-LEFT: windowtext 0.5pt solid; BACKGROUND-COLOR: fuchsia; WIDTH: 698pt; HEIGHT: 13.6pt; BORDER-TOP: windowtext; BORDER-RIGHT: windowtext 0.5pt solid" class=xl27 height=18 width=931>Reservoir screen Int. # 1838526C1</TD></TR><TR style="HEIGHT: 27.2pt" height=36><TD style="BORDER-BOTTOM: #d4d0c8; BORDER-LEFT: #d4d0c8; BACKGROUND-COLOR: fuchsia; WIDTH: 698pt; HEIGHT: 27.2pt; BORDER-TOP: #d4d0c8; BORDER-RIGHT: #d4d0c8" class=xl25 height=36 width=931>3C3Z-6A642-CA is the part number for the oiler REPAIR KIT. ($200-300)ebay
3C3Z-6A642-AA is the complete cooler .($400-600) ebay</TD></TR><TR style="HEIGHT: 13.6pt" height=18><TD style="BORDER-BOTTOM: #d4d0c8; BORDER-LEFT: #d4d0c8; BACKGROUND-COLOR: fuchsia; WIDTH: 698pt; HEIGHT: 13.6pt; BORDER-TOP: #d4d0c8; BORDER-RIGHT: #d4d0c8" class=xl25 height=18 width=931>FTE thread entitled my 68.17 EGR delete - also discusses the oil cooler</TD></TR><TR style="HEIGHT: 13.6pt" height=18><TD style="BORDER-BOTTOM: #d4d0c8; BORDER-LEFT: #d4d0c8; BACKGROUND-COLOR: fuchsia; WIDTH: 698pt; HEIGHT: 13.6pt; BORDER-TOP: #d4d0c8; BORDER-RIGHT: #d4d0c8" class=xl25 height=18 width=931></TD></TR><TR style="HEIGHT: 13.6pt" height=18><TD style="BORDER-BOTTOM: windowtext 0.5pt solid; BORDER-LEFT: windowtext 0.5pt solid; BACKGROUND-COLOR: fuchsia; WIDTH: 698pt; HEIGHT: 13.6pt; BORDER-TOP: windowtext 0.5pt solid; BORDER-RIGHT: windowtext 0.5pt solid" class=xl27 height=18 width=931>Oil Cooler is under the oil filter:</TD></TR><TR style="HEIGHT: 27.2pt" height=36><TD style="BORDER-BOTTOM: windowtext 0.5pt solid; BORDER-LEFT: windowtext 0.5pt solid; BACKGROUND-COLOR: fuchsia; WIDTH: 698pt; HEIGHT: 27.2pt; BORDER-TOP: windowtext; BORDER-RIGHT: windowtext 0.5pt solid" class=xl27 height=36 width=931 x:str="there are 2 nuts on the top both are 13mm. there are 2 bolts on the bottom both also 13mm. set cooler housing on small blocks so the element is off the ground and then tap apart with a hammer from the 2 ports. ">there are 2 nuts on the top both are 13mm. there are 2 bolts on the bottom both also 13mm.
set cooler housing on small blocks so the element is off the ground and then tap apart with a hammer from the 2 ports. </TD></TR><TR style="HEIGHT: 12.9pt" height=17><TD style="BORDER-BOTTOM: windowtext 0.5pt solid; BORDER-LEFT: windowtext 0.5pt solid; BACKGROUND-COLOR: fuchsia; WIDTH: 698pt; HEIGHT: 12.9pt; BORDER-TOP: windowtext; BORDER-RIGHT: windowtext 0.5pt solid" class=xl28 height=17 width=931>https://www.ford-trucks.com/forums/902962-oil-cooler-r-and-r-help.html</TD></TR></TBODY></TABLE>

 

I assume you mean plug the exhaust inlet to the EGR cooler!

 

yes that's what I mean.

 

I knew you meant that, but it might have read a little differently to a newbie. Hope you don't mind the clarification.

 

Between the great writeups on FTE and the writeup at the following link Ford Powerstroke Diesel Forum it sure is making the job a lot easier for me. Mine is all tore down, oil cooler is rebuilt and now I am waiting on gaskets from the dealer. I really want to start putting things back together but I have to make the EGR delete mods first. Good luck I hope the link I provided helps, I know it helped me. There is also a thread titled "my $68.17 full EGR delete" that Scott posted. He made a great writeup on how to delete the egr cooler on the cheap. I followed his instructions with a few, ok a lot of questions answered by him but I am almost there. If you have any questions, let me know as I am in the middle of it right now and could help if you need advice. Good luck

 

What's going on with all these oil coolers going out at the same time?

 

Well we tore it down on Friday and thanks to everyone's help on FTE we had no problem's except when we diconected fuel supply line going to the head on the right side the conecting nut was corroded to the fuelfilter/oil filter housing and we had to cut it off, so we have new one coming today. We cleaned everyting up, rebuilt the oil cooler and put it back together as far as we could go. One thing we noticed was when the oil cooler was off we looked down in the port that must feed the oil cooler with water and there was a lot of (i assume) casting sand and we cleaned out as much as we could, it was unbeleaveable how much grit we found in there. When we drained the cooling system the coolant looked like 10w motor oil!
Well anyway we will be making fire later today and we are installing a water filter and trying a new cooling system flush solution along with the ford one, VC-9 in seperate flushes.. One thing we did as far as cleaning the top of motor off was, before we pulled the oil cooler and the intake we pluged ALL ports and openings and took compressed air and blew all the sand and crap off the top of engine and then cleand the area around the oil cooler with brake cleaner before its removeal, it seemed to clean it up real good.

Thanks again to everone, for your input!

 

Sounds like you have everything well in hand.
That cleaning job may have saved you a IPR.

 

All is working great! We put in the new flash as of 11-25-09 (TSB 09-24-3). found out truck was running a little cold so we installed new thermostat. We also installed dieselsite waterfilter kit, after a few days of plowing snow the filter ia already full and needs to be replaced, the truck has not even been running a week!
I am planing on cutting the old oil cooler apart to see what it looks like inside and just how much debris (casting sand) is in there.

Later

 

you should check both side of the oil cooler if you are going to cut it open. the oil side also like to plug sometimes.

 

I want to cut mine open as well. I imagine a hacksaw will work just fine. I was going to use the sawzall but I can imagine oil flying everywhere..