Backflush an Oil Cooler on a 2003 to 2007 Powerstroke

Background information:The purpose of this section is to provide a brief overview on why you need to backflush the oil cooler on your 2003 to 2007 Ford truck with the 6-Liter Powerstroke engine. This engine utilizes an oil cooler to keep engine oil temperatures to a minimum by cycling engine coolant through the cooler. As the coolant cycles through the oil cooler, heat is transferred from the oil to the coolant. As the coolant exits the oil cooler it makes it way to the radiator, where the heat is dissipated. Ford recommends a 15-degree Fahrenheit delta (difference) between the oil and coolant temperatures at highway speeds. If the delta exceeds 15 degrees, then it is possible that the oil cooler is not transferring heat effectively, which could be caused by a multitude of things including, plugged/contaminated oil cooler, low coolant level, blown head gaskets, oil in the coolant, etc. This instruction set is to primarily focus on oil coolers that are plugged or partially plugged and how back flushing can be added as a routine preventative maintenance procedure. Introduction:The purpose of this document is to give the step-by-step process of how to backflush the oil cooler on a 2003 to 2007 Ford truck with the 6-liter Powerstroke engine. Each step will include a detailed description and pictures to help aid in this process. Along with the instructions, there will also be hints and tips to ensure the repair/preventative maintenance procedure is done properly with no errors.

Steps

  1. First step is to gather yours tools, these include:
    • T30 Torx bit
    • Ratcheting bit holder
    • 6.0 Powerstroke oil cooler backflush kit
    • Back Flush gun
    • Air compressor
    • Garden Hose
    • Step stool
    • 5 gallon bucket
    • Large drain pan
    • 5/16 socket and ratchet
    • Flashlight
  2. Note: This prevents the vehicle from rolling or starting while carrying out the repair.
    • Park the truck on a level surface and block the wheels.
    • Remove the key from the ignition, pop the hood, and disconnect the batteries.
  3. Drain the coolant:
    • Put the large drain pan or clean 5 gallon bucket under the lower radiator hose.
    • Using the 5/16" socket and ratchet, loosen the lower hose.
    • Allow coolant to drain completely.
  4. Removing the Oil cooler outlet cover:
    • Locate the oil cooler outlet on the top of the engine, in front of the turbocharger.
    • Remove both T30 torx bolts that retain the oil cooler outlet cover
    • Remove the cover.
  5. Install the garden hose adapter plate (part of the 6.0 Powerstroke backflush kit)
    • The bolts that were removed will be needed to hold the adapter down.
  6. Hook up the backflush gun:
    • Hook the garden hose to the backflush gun
    • Hook the air compressor to the backflush gun
    • Hook the garden hose adaptor mounted to the truck to the backflush gun
  7. Flush the cooler:
    • Allow water to run through the oil cooler and out the lower radiator hose for 10 minutes.
    • Depress trigger on backlfush gun in short bursts to dislodge any contaminants in the oil cooler.
  8. Detach the backflush gun from the adapter.
  9. Install the original coolant outlet cover on the truck using the T30 Torx bolts.
  10. Install the lower radiator hose:
    • Tighten the clamp with the 5/16" socket and ratchet.
  11. Pour new coolant into the system until full.
  12. Hook up the batteries:
    • Positive terminals first, negative last.
  13. Bleed the air:
    • Allow truck to idle for at least 30 minutes with the coolant resevoir cap off.
  14. Inspect for leaks:
    • Inspect lower radiator hose for leaks.
    • Inspect oil cooler outlet cover for leaks.

Tips

  • Tip: There may be additional tools needed throughout the process of backflushing the oil cooler, for example, if you loosen up the lower radiator hose at the radiator and you cannot break the seal, then use a long straight pick to assist.
  • Tip: Removing the coolant reservoir cap while the coolant is draining will speed up the draining process.
  • Tip: Use the 90-degree Torx bit on the bolt that is under the compressor side of the turbo and use the standard Torx bit in the ratcheting holder on the other bolt.
  • Tip: To aid in breaking the seal on the coolant outlet cover, use the grip side of the screwdriver and lightly tap.
  • Tip: Looking in the drain pan, pay attention to debris and sand like material at the bottom. These are contaminants that create blockage in the oil cooler and reduces its overall cooling efficiency.
  • Tip: Utilizing a cooling system vacuum filler will ensure there are no air bubbles in the system.

Warnings

  • Skipping Step 2 could result in serious harm!

References

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