i will post the newest tsb for coolant bottle overflow here it is it may help some as if you have the egr cooler blocked off you could jump right to test for headgaskets
FORD: 2003-2005 Excursion
2003-2007 F-Super Duty
This article supersedes TSB 07-14-5 to update the Part List.
Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2007 E-Series vehicles, all equipped with a 6.0L engine, may exhibit coolant venting from the degas bottle cap. The condition typically occurs when operating the vehicle under a load such as trailer towing, uphill driving, or both.
Prior to making any repairs, verify the coolant level is not overfull. The new 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. If the degas bottle is not overfull, and is still venting out coolant, refer to the following Service Procedure.
Complete All Steps In Order As Outlined
Check for cross contamination of engine oil into cooling system by inspecting the coolant condition in the degas bottle. If oil is present in coolant, perform the following repair:
Replace the oil cooler, refer to Workshop Manual (WSM), Section 303-01C.
NOTE: ON 2004 E-SERIES 6.0L BUILT BEFORE 05/29/2004: IF THE OIL COOLER IS REPLACED, ALSO REPLACE THE HEATER CORE INLET HOSE; THE REVISED HOSE CONTAINS AN INTERNAL FLOW RESTRICTOR (FIGURE 1). REFER TO TSB 05-2-5 FOR ADDITIONAL INFORMATION.
Figure 1 - Article 07-21-5
Clean cooling system with VC-1 Motorcraft® Premium Cooling System Flush. Refer to WSM Section 303-03.
NOTE: IT MAY BE NECESSARY TO FURTHER REMOVE ALL COOLANT HOSES (RADIATOR, DEGAS, AND HEATER) AND CLEAN THEM SEPARATELY. OIL TENDS TO ADHERE TO THE RUBBER AND RESISTS NORMAL FLUSHING.
NOTE: IN EXTREME CASES, THE RADIATOR MAY NEED TO BE REMOVED AND CLEANED IN AN ULTRASONIC CLEANING TANK AT A LOCAL RADIATOR REPAIR FACILITY.
Check for diagnostic trouble codes (DTCs). Then using IDS datalogger, access the following PIDs and road test the vehicle:
Manifold Gauge Pressure (MGP)
Barometric Pressure (BARO)
Exhaust Gas Recirculation (EGR)
Exhaust Pressure (EP)
Mass Air Flow (MAF)
Manifold Absolute Pressure (MAP)
Engine Coolant Temperature (ECT)
Engine Oil Temperature (EOT)
Verify that MGP, BARO, EGR, EP, MAF and MAP PIDs are within specification, and the EP PID value is within 1.5 psi (10.34 kPa) of the MAP and BARO PID values with key on engine off (KOEO). If PIDs are not within specification, or DTCs are retrieved, refer to PC/ED pinpoint tests. Repair any faults then proceed with the TSB.
NOTE: OVER-BOOST CONDITIONS (HIGHER THAN SPECIFIED MGP) WILL RESULT IN EXCESSIVE CYLINDER PRESSURES, AND MAY BE CAUSED BY ONE OF THE FOLLOWING: IRREGULAR RESPONSE IN VARIABLE GEOMETRY TURBO, BIASED EXHAUST PRESSURE SENSOR, AND/OR IRREGULAR EXHAUST GAS RECIRCULATION.
Verify that ECT and EOT PIDs are within specified ranges (see PC/ED Section 1: Description and Operation of ECT, EOT). EOT should be about 225° F (107° C) when the ECT is 200° F (93° C). If EOT IS NOT within 25° F (14° C) of ECT during the concern, replace the oil cooler. However, first perform all steps through Step 5 before replacing the oil cooler. Refer to Workshop Manual, Section 303-01C.
Check for proper operation of the pressure cap and its seal to the degas bottle. Do not remove the pressure cap. As shown in (Figure 2), install the pressure tester to one (1) of the two (2) small ports near the top of the bottle. Then isolate the degas bottle by securely pinching off (or plugging) the other intake deaeration (small) line, and the large hose at the bottom of the bottle between the bottle and the tee fitting. Pressurize the degas bottle by using slow and steady pushes on the tester pump handle (not quick jerking pushes). Pressurize the degas bottle until the gauge pressure levels off, typically between 12-18 psi (83-124 kPa).
Figure 2 - Article 07-21-5
Wait 30 seconds, if the gauge holds steady pressure, the pressure cap and degas bottle fill neck lip are good.
If the gauge pressure drops, apply soapy water around the cap to find any leaks. Check the degas bottle fill neck lip for nicks or cracks. Small nicks can be removed by light sanding with fine emery cloth. Re-pressure test, if leaks are still present replace the pressure cap. Re-pressure test again, if leaks are still present replace the degas bottle, Refer to WSM, Section 303-03.
After verifying that the degas bottle and pressure cap are in good condition, proceed to Step 4.
NOTE: A DEFECTIVE EGR COOLER CAN CAUSE COOLANT TO VENT OUT OF THE DEGAS BOTTLE AND APPEAR SIMILAR TO HEADGASKET FAILURE.
EGR COOLER TEST: Install a pressure tester in-line with the degas bottle hose using Rotunda 014-R1068 adapter. (Figure3)
Figure 3 - Article 07-21-5
Pressurize the cooling system until the gauge pressure levels off.
Inspect for external leaks especially in the heater core area. Replace the heater core if necessary, refer to Workshop Manual, Section 412-02. Refill the system and proceed to Step 4c.
NOTE: ON 2004 E-SERIES 6.0L BUILT BEFORE 05/29/2004: IF THE HEATER CORE OR OIL COOLER ARE REPLACED, ALSO REPLACE THE HEATER CORE INLET HOSE; THE REVISED HOSE CONTAINS AN INTERNAL FLOW RESTRICTOR. REFER TO TSB 05-2-5 FOR ADDITIONAL INFORMATION.
Raise rear of vehicle 2' (61 cm) so front of vehicle is angled down. Pressurize cooling system with pressure tester and remove the EGR valve; inspect for coolant in the intake manifold at EGR valve location. Maintain pressure for up to 15 minutes. An EGR cooler gross leak will produce coolant in the intake manifold almost immediately. It will take up to 15 minutes for coolant to be evident in the intake manifold for the smallest EGR cooler leak. If coolant is present in intake replace the EGR cooler; refer to WSM, Section 303-08. (Normally when the EGR cooler has failed, there will be coolant in the exhaust. Hydro locking of the engine is also possible.) Refill the system and proceed to Step 5.
NOTE: REPLACE THE OIL COOLER AT THIS POINT IF NECESSARY AS OUTLINED IN STEP 2.
CAUTION: COOLANT ENTERING ANY COMBUSTION CHAMBER MAY CAUSE A HYDRO LOCK CONDITION. EVACUATE INTAKE PASSAGES AND COMBUSTION CHAMBERS OF ALL LIQUIDS. REMOVE GLOW PLUGS (REFER TO WSM, SECTION 303-07B) TO ASSIST IN VENTING LIQUID FROM COMBUSTION CHAMBERS, BEFORE ENGINE IS STARTED.
With the pressure tester still installed as outlined in Step 4, release cooling system pressure, leaving the tester in place. Seal pressure bleed. Drive the vehicle at Wide Open Throttle (WOT) / high load / maximum boost. Observe whether the cooling system pressure exceeds the holding pressure of 12-18 psi (83-124 kPa) noted in Step 3, and/or if coolant is venting through the degas bottle cap.
If pressure is not greater than the holding pressure noted in Step 3, and no venting from the degas bottle occurs, perform Step 7 (if applicable) and return the vehicle to the customer.
If cooling system pressure is greater than the holding pressure noted in Step 3, and/or the degas bottle cap vents, replace the head gaskets. Refer to WSM, Section 303-01C for head removal/installation and head flatness specification, check the surface of the heads for flatness and/or imperfections. Refer to WSM, Section 303-00 for the cylinder head flatness measuring procedures. Use the following revised head bolt torque sequence and specifications. (Figure4)
Figure 4 - Article 07-21-5
Ensure the cooling system has been thoroughly flushed if any contamination had occurred, and new antifreeze is installed after all repairs have been completed. Refer to WSM, Section 303-03. Make certain to follow the cooling system air bleed procedure, or additional failures may result.
For 2004 (built after 9/29/03)- 2006 F-Super Duty and 2004 (built after 9/29/03) - 2005 Excursion: reprogram the powertrain control module (PCM) to the latest calibration using IDS release B39.12 and higher. This calibration contains a revised cooling fan strategy to help reduce the occurrence of coolant venting. Calibration files may also be obtained at www.motorcraft.com
CYLINDER HEAD HANDLING
Avoid banging, dragging or scratching the cylinder head at all times. When removing the cylinder head, lift the cylinder head straight up off of the dowels so as not to nick the cylinder head.
Once the cylinder head is removed, place the cylinder head on a bench with the gasket side up. If the gasket surface must be turned down, use a piece of clean cardboard on the bench surface to protect the cylinder head from damage. Do not allow the cylinder head to slide on the gasket surface, even on cardboard.
CLEANING THE CYLINDER HEAD AND DECK SURFACE
The only tools approved by Ford Motor Company for cleaning the cylinder head and deck surface are plastic (Figure 5) and wood scrapers, combined with use of Ford approved cleaners. Ensure that the mating cylinder block deck surface is completely free of solid contamination, corrosion, and fluids.
NOTE: STAINING OF THE METAL SURFACE IS CONSIDERED NORMAL AND DOES NOT AFFECT SEALING ABILITY.
CAUTION: DO NOT CLEAN DECK SURFACES UNDER ANY CIRCUMSTANCE WITH STEEL RAZOR BLADES, ROTARY ABRASIVE DEVICES, OR ABRASIVES INCLUDING: ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS OR EQUIVALENTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVES SUCH AS SANDPAPER OR EMERY CLOTH, ANY CARBON STEEL BLADE. THESE PRODUCTS WILL CUT AND DAMAGE DECK SURFACES RESULTING IN LEAKS. ABRASIVE PARTICLES MAY ALSO ENTER THE ENGINE CAVITIES CAUSING INTERNAL ENGINE DAMAGE. USE OF THESE TOOLS CAN ALSO GREATLY AFFECT THE FLATNESS OF THE SURFACE.
well i hope this will help someone here