the truck has about 145000 miles on it and i just talked with a guy form ATG manuals. He also suggested the EGR cooler but i' having no luck locating it. Also I just got back from a road trip. I drove about 80 plus for about 220 mile and had to fill the tank back up but on the way back I drop about 65 to 75 and got about 350 plus miles before filling back up. Maybe this will help

 

Hmmm. An ERG cooler? ...an Exhaust Gas Recirculation [valve] cooler? Whazzat? That sounds like a gas burner solution to a oil burner problem.

Get back to the basics. Coolant is going somewhere and you can't see any signs of it. That means is going someplace hidden, like the cylinders. No sign of milkiness in the oil? No sign of moisture at the tailpipe?

As much as you don't want to do it, you are going to have to dig back into the engine. Take the head off again and have it checked for cracks (magnafluxed). Any good machinist will take care of you.

Some head cracks can be repaired, some cannot. Good luck.

 

Being that is is an 02, i would have to guess it is a federal emissions truck so it does not have an egr or cooler. Theres a few places coolant can run off too.

Injector sleves, Waterpump, HG, Loose hose, Loose drain valve, Bad cap, hole in rad, loose turbo banjo bolt on the turbo, bad coolant crossover tube gaskets.


one thing i think you should do is go to a napa store and get yourself a coolant test kit, the cheap one will do fine. see if there is any oil contamination in there. Another thing you can do is let the tuck sit over night and pull the glow plugs and see if there is any coolant in the cylinders.



Its an aluminum head, cant magnaflux unfortunately , but the machinist can find cracks in the head if he has any using dye penetrant or w/e

 

did you find your leak? I would start with the water pump.

 

U ever figure out what was leaking