Diesel Engine - Oil/Boost Leaks At Hot Side CAC Duct
TSB 07-5-1503/19/07
6.0L - OIL SEEP OR BOOST PRESSURE LEAK AT
HOT SIDE CHARGE AIR COOLER DUCT
FORD:
2003-2005 Excursion
2003-2007 F-Super Duty
This article supersedes TSB 07-3-1 to update the Service Parts.
ISSUE
Some 2003-2005 Excursion and 2003-2007 F-Super Duty vehicles, equipped with the 6.0L diesel engine, may exhibit oil seepage or a boost pressure leak at the hot-side charge air cooler (CAC) duct assembly connections.
ACTION
The hot-side CAC duct is no longer available as an assembly. Should CAC repairs become necessary, individual components must be ordered to rebuild the duct assembly. Refer to the Service Tips.
SERVICE TIPS
1. Carefully inspect all components for holes, tears, cuts, abrasion, oil saturation or sponginess, and order only the components needing replacement. Use new clamps rather than reusing the old.
2. Thoroughly clean all components, both new and reused, especially in the joint clamp areas, as well as the turbo and CAC connections, using PM-4 Motorcraft Brake Cleaner.
3. If the curved turbo hose must be replaced, mark the metal duct adjacent to the faint white alignment mark on the old hose (top position in vehicle) before removing it from the duct. Then install the new hose so its alignment mark is adjacent to the mark made on the metal duct. Position and torque clamps.
4. Carefully reinstall the rebuilt duct assembly. Torque all four (4) clamps to 9 lb-ft (12 N.m) only; over tightening will damage the component. Check all joints for leaks using soapy water.
NOTE
BEFORE REBUILDING AND INSTALLING THE DUCT, OBSERVE THE COLOR OF THE INSIDE SURFACE OF EACH HOSE.
If Blue (B)
a. Apply a thin uniform coating of TA-31 Motorcraft RTV Silicone Sealant to the sealing surfaces of the hose and to the mating duct and fitting.
b. After reassembly and reinstallation, allow to cure for three (3) hours before starting the engine. These steps will help prevent joint separation.
If Red-Orange (R-O)
a. Do not apply any sealant/adhesive, as this hose has inherent adhesive properties.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C646 42
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