2003 Ford F250 Powerstroke Oil leak after oil cooler replacment
 

Hello all, just purchased the F250 a short while ago from a "friend". It was supposed to have the EGR delete and other maintenance done to it. After just having the oil cooler and EGR cooler fail, I've found I have a small basket case!

I just finished putting it together with a EGR delete and new oil cooler. I reused the old oil cooler plate assembly. After starting the truck, I have two issues
1: Exhaust leak at the uppipe to turbo (easy enough)

2: Major oil leak while running. It comes from the EGR cooler jacket area towards the front. Here are two pictures before/after. Assembled with all new ford O-rings and gaskets. Trying to get advice before I tear it back apart.
Attachment 32281
Attachment 32282

Other maintenance done-
New water separator manifold
Billet fuel filter cap
Blue spring upgrade
Clean/repaired turbo
Flushed coolant and replaced with ELC and distilled water

you have to remember that the oil resivoir for the HPOP us pressurized to about 75psi so a if that oring/the crazy one under the housing/ is off a little it will create a large leak. make sure all the bolts are tight

Thanks Bob, the leak is from the multilayered area by the egr cooler. Is it possible it cracked? One bolt broke there and I drilled it out and tapped it for a new bolt. I torqued it to spec. Is there coolant in that area too? I guessi need to take it apart. ={

Just to follow up, it was a O-ring that pinched on the cooler as it slid into the base plate.

Just did it's first full test drive last night and its off to work today since the repairs, holy cow it's a different truck than before. It's amazing when everything is right how much it screams! Had someone is a Duramax2500 learn a valuable lesson about the 6.0!