Would Ford really do this??!!
 

Have 2004 F250 Super duty crew cab 4x4 with the 6.0 turbo. Within last 2 years have replaced the EGR twice and the inter cooler once (yup, have been told that is why I had to do the EGR a second time) Had the turbo torn down and serviced with install of the second EGR. So truck (less than 180,000 kilometers) is running great, much smoother and oddly enough seems to have better fuel economy. But here is my question.
My new mechanic (a former senior Ford diesel teck) told me this problem came from when Ford cast the engines. He s aid that they were unable to get all the sand out of the oil galleries and so looked at how long the engines would last before failure of a component. They determined that it would be when the vehicles were off warranty and so ignored the potential problem. Can this be true?? He says he has cut inter coolers apart and they are plugged with casting sand from manufacture. Has anyone else been told the same?
He also recommends that I should replace the oil cooling rad to ensure I have all the sand out of the system. Yes or no? What do you think?
This mechanic (owns his own small shop) saved me big dollars when my high pressure oil pump blew and took an attached control item with it. So far he has not steered me wrong but really wondered about his comments on:argh: Ford.

Thoughts?

Tagged, so I will learn


But I wouldn't put anything past the beancounters for any manufacturer.

DS

sent from the Honey Badger Nexus

Since the intercooler is used to cool the air entering the motor I doubt there is casting sand inside.

I've heard of problems with casting sand in the oil coolers on the coolant side which can lead to EGR cooler problems. I would change out the cooler and put in a coolant filter setup.

Thanks Heavy Assault...but think there has been a misunderstanding, possibly in the terminology I used??

I would do a good radiator flush after changing the oil cooler and add a coolant filter to help keep the sand from getting any further. also you shouldnt be leaking that much into your intercooler cause you would be blowing blue and white smoke from all the oil and coolant getting in there.

Did you end up blocking the EGR entirely?

No the EGR was replaced (again). Can not delete here due to mandatory and fairly strict emissions test that due to vehicle size must be done annually to get licensed.

Where are you from the emissions are so strict? California?

A lot of people swear that Ford coolant is the best but I would disagree after replacing my oil cooler. I found a significant amount of white residue in my degas bottle and around all the coolant hose connections. It reminds me of lime scale from hard water. Before Ford redid the fill level on the degas bottle the coolant that it puked up left a white residue on the black top of the bottle. I know it wasn't from the lack of maintenance, my truck only saw that wonderful gold coolant and distilled water. I had my EGR cooler welded up, added a coolant filter and switched to Rotella ELC.