Section 03-01D: Engine, Diesel, 7.3L | 1996 F-Series Workshop Manual |
If oil is found in the cooling system, or coolant found in the oil, the oil cooler (6A642) should be checked for leakage as outlined under Oil Cooler Internal Leakage Test in the Service Procedures portion of this section.
If oil cooler O-rings are leaking, remove oil cooler. Refer to Engine Oil Cooler in the Removal and Installation portion of this section. Disassemble and repair as follows.
Disassembly
Gently rap front header and rear (oil filter) header to loosen O-rings. Twist oil cooler apart.
Clean oil cooler, front header and rear header thoroughly in suitable solvent. The oil cooler should be thoroughly flushed and drained to remove all residue within it.
| Item | Part Number | Description |
|---|---|---|
| 1 | 6A636 | Gasket, Oil Cooler Front Header |
| 2 | 6881 | Header, Oil Cooler Front |
| 3 | 6K649 | O-Ring, Oil Cooler Inner |
| 4 | 6C610 | O-Ring, Oil Cooler Outer |
| 5 | 6A642 | Oil Cooler |
| 6 | 6A636 | Gasket, Oil Cooler Rear Header |
| 7 | 6881 | Header, Oil Cooler Rear |
| 8 | — | Plug (Part of 6881) |
| 9 | 6731 | Oil Filter |
Assembly
Use new O-rings when assembling oil cooler. Lubricate all O-ring mating surfaces and O-rings prior to assembly with clean engine oil.
Install the large O-rings on the oil cooler first, then install the small O-rings on the oil cooler.
| Item | Part Number | Description |
|---|---|---|
| 1 | 6881 | Header, Oil Cooler Front |
| 2 | 6C610 | O-Ring, Oil Cooler Outer |
| 3 | 6A642 | Oil Cooler |
| 4 | — | Flange (Part of 6A642) |
| 5 | 6K649 | O-Ring, Oil Cooler Inner |
Press assembly together, making sure locating clips align in slots and header is not cocked.
Test oil cooler before installing on engine.