how to reseal oil cooler on the 6.9, 7.3 and 7.3 powerstroke engine.

after draining coolant from radiator and block(if not drained from block u will make a mess when cooler is removed) remove the cooler from the engine. will need to unbolt the driverside motor mount and jack the engine up to get the cooler out. it is a tight squeeze but is possible. some oil and coolant will come out when cooler is removed, just dont have your mouth open when it does.


clean the oil cooler as best as possible in parts washer or the like. will look like this.


now place in a vice and tap off the end caps with a rubber or plastic hammer. the end caps are aluminum and will crack if hit to hard. tap them off by hitting here


now after taking the end caps off, remove the old orings. clean the core the best you can, making sure the oring lands are clean and burr free.



now clean the end caps also, paying close attention to where the core slides in. you do not want any burrs here that can cut the oring.



place the new orings on the core and put a coat of oil on them to help them slide into the end caps.



now comes the fun part. since many of us do not have a press, which is the correct way to put the end caps on, use a floor jack and something heavy. i used my welding table. can use bumper of truck, tractor, whatever. press the end caps onto the core making sure the alignment tab is lined up with the slot on one end cap. do not worry about the other cap, it can be turned after fully pressed on.



now rotate the other end cap and done! reinstall and enjoy your leak free cooler.



orings can be had from ford or international. the block to cooler gaskets can be had from any parts store. u will get three gaskets, one will not be used. it is for the van oil coolers.