'03 6.0 Leaking Coolant - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 11 (permalink) Old 05-17-2015, 05:44 AM Thread Starter
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'03 6.0 Leaking Coolant

For no apparent reason, my truck decided to start leaking coolant. It was a very noticeable drip. With the truck parked on a slight incline (front high) the drip was coming off the back of the engine.

I topped up the reservoir and then applied low pressure air (regulated 15psi) into the reservoir. Any higher and the pressure relief cap started to release. The cap is a 16psi relief. I removed the vent tube coming from the radiator and plugged it and then connected my air nozzle directly to the reservoir.

With the pressure applied and some close inspection with a good light, I found the source. It was the donut o-ring on the bottom of the intake manifold towards the front. There is only a few places coolant can escape in that area. I checked the easy things like the little blue hose between the oil cooler and the EGR cooler and they were all dry.

Several hours later, the intake was out and the culprit was identified. Once again, a 10 cent part takes out the whole engine.

What causes the rubber to deteriorate? Check out the picture. Its been a long time since I had this apart so I don't know how long exactly but I can figure about 100k miles and 5 or more years.

I also took some better pictures of my ICP relocation. I thought about removing the HPOP cover and the oil cooler for an inspection, but decided better to leave well enough alone. I'm having no other symptoms that would warrant digging deeper.
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2003 F250 6.0L Crew Cab
All factory stock. 225k miles.

Its Just A Machine and Machines can be fixed!
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harry6.0 (05-17-2015), jsm180 (05-17-2015), TooManyToys (05-17-2015), Weld engineer (05-19-2015)
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post #2 of 11 (permalink) Old 05-17-2015, 12:12 PM
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Were you able to find just the o ring? If so do you have a part number?

2003 F-250 CC SB FX4 Lariat Black on Gold
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post #3 of 11 (permalink) Old 05-17-2015, 02:54 PM Thread Starter
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The donut came as part of a gasket kit. I didn't use all the parts. I used the blue hose and the large metal ring gasket. The other two parts are for the EGR cooler (which I have not deleted) and this time I did not separate it from the intake.

The parts guy at the Ford dealer was able to bring up several exploded parts views that had everything called out.

I'm still curious as to why the donut deteriorated in the first place. I suppose in another 100K or so I'll be doing this job again.

When I bought the truck new, I said I was going to keep it until the wheels fall off. So far that has not happened but the engine has had its share of problems. Would I buy a Ford again? Probably. Not because Ford is the greatest truck ever but I have all the tools and experience working on this one and I would hate to have to start over learning the problems and techniques of another manufacturer.

I cant imagine the thousands of dollars I would have spent taking it to the dealer or some other shop for repairs. I can give lots of credit to TheDieselGarage and all the guys that participate in helping spread the knowledge. Thanks guys!
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2003 F250 6.0L Crew Cab
All factory stock. 225k miles.

Its Just A Machine and Machines can be fixed!
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post #4 of 11 (permalink) Old 05-17-2015, 03:03 PM
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Nice pic's!

I really like the icp relocation setup.

As for the oring, looks to be crappy material, just make sure no fuel in coolant is occuring as that can have an effect on cooling system rubber components.

Harry

Jan 03' built 6.0/F250cc4wd trqsft/SCT-tuned by KEM-Performance/Garrett Powermax vg-turbo/blue spring mod/gauges=egt+boost+fuel+SG2/exhaust/airaid intake/DR 4.5 lift/dual bilsteins/315's/greasable ball joints/powerstop/smittybuilt/kc lights/high idle mod/roll-n-lock/Mobil Delvac1 ESP 5W40 with (Archoil AR9100 in the oil) and (AR6200 in the fuel)
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post #5 of 11 (permalink) Old 05-17-2015, 07:24 PM
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Oil (if you ever had an oil cooler leak) and heat can also be hard on gasket material in the cooling system.

I believe that the donut by itself is International part # 1836551C1

http://www.ford-trucks.com/forums/13...et-solved.html

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06 F250 CC SB FX4 Lariat;ARP studs;OEM gaskets;Banks exhaust;DynaTrac Ball joints;Coolant filter;High-Idle mod;RACCCV6000;JimmiJammers;Ravelco;SynchroMax xfer case;Fumoto valve;Harpooned;CPOhighwayProducts toolbox;tracrac;Fox Weatherboots;Wet Okole Seat Covers;BriteBox;Re-flashed;Quadzilla Recon XZT Fuel Press;Blue FPR spring;DashDAQ;PHP FICM;RiffRaff boots;DCPower270AXP;PowerInverter;Rancho7000's;BPD EGR cooler;One-piece HPOP fitting;D-plugs&standpipes;BPD BilletWaterPump;SCT w/ Matts SRL+;ELC Ultra;DuraTracs

Last edited by bismic; 05-17-2015 at 07:38 PM.
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post #6 of 11 (permalink) Old 05-17-2015, 09:14 PM
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I'm surprised it failed. You would have to know what rubber compound it is to know what would deteriorate it, but .....

Coolant system and brake component rubber material are typically EPDM rubber. This is a water-compatible and glycol-compatible material...but doesn't like petroleum oils. Looking at the picture it deteriorated on one contact surface only, not both or from the inside, before rupturing its ring configuration. It is possible you used a petroleum grease or oil on one surface when putting it back together to hold it in place? I know when I did an oil cooler But I used silicone grease to do so. Silicone grease is kind of universal in not effecting rubber so that is what I always use with rubber contact, especially if in use with any glycols, i.e. brake and cooling fluids.

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Step Lights;Painted Flanges; Bypass Oil Filter; Heated Mirror Switch; Reverse Lights; 7.3L Fuel Reg Shim; 6 Disc Radio Speed Volume Mod; Coolant Filter, etc.

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post #7 of 11 (permalink) Old 05-18-2015, 01:34 AM
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I didn't notice the ICP relocation until Harry mentioned it. That is nice! And that seal number from Bismic is correct, you cannot get just that seal from ford.

Last edited by lenzhotrod; 05-18-2015 at 01:39 AM.
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post #8 of 11 (permalink) Old 05-18-2015, 05:47 AM
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I remember when Fixinit did the icp relocation yrs ago, but I don't recall a full view pic like this thread.

Cooling system and fuel system orings can get rock hard and fail, heat and time are usually the culprits, and they break apart when trying to remove them, but this one looks more unusual than the norm.

What kind of coolant maintenance has this engine seen?

Harry

Jan 03' built 6.0/F250cc4wd trqsft/SCT-tuned by KEM-Performance/Garrett Powermax vg-turbo/blue spring mod/gauges=egt+boost+fuel+SG2/exhaust/airaid intake/DR 4.5 lift/dual bilsteins/315's/greasable ball joints/powerstop/smittybuilt/kc lights/high idle mod/roll-n-lock/Mobil Delvac1 ESP 5W40 with (Archoil AR9100 in the oil) and (AR6200 in the fuel)

Last edited by harry6.0; 05-18-2015 at 05:50 AM.
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post #9 of 11 (permalink) Old 05-18-2015, 08:44 AM
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Upon closer inspection isn't that turbo oil line the older style that is known to come apart inside? Do you happen to have fitting numbers for your relocation setup on the ICP?

Last edited by lenzhotrod; 05-18-2015 at 08:46 AM.
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post #10 of 11 (permalink) Old 05-18-2015, 02:38 PM Thread Starter
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Lenz Don't scare me. All I need is something else to blow up! I just had it apart and cleaned everything in the valley. I think I have had my share of misfurtunes.

My coolant maintenance is probably not up to par. But it seems like I have the engine apart often enough and the coolant gets changed then anyway. I had been using the red stuff from International. It always came out looking just like it did going in.

What should I do on a regular basis?

When I did the relocate job awhile back, the pics down in the valley were not real good. I have a new phone with a better camera now so I took some new pics. The original thread has some good pics of the ICP up on top

2003 F250 6.0L Crew Cab
All factory stock. 225k miles.

Its Just A Machine and Machines can be fixed!
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