Ford Excursion :: Intercooler Leaking - Causes?
May 9, 2015
Saw a decent amount of oil residue and when I pulled the intercooler there were areas of the plastic deformed and a fairly large oil/air leak.
Truck is completely stock (93K miles) so was wondering what root cause of this might be? Just a failure of the component from age? Boost too high, suggesting an issue with the turbo?
CAC boot that connected closest to the damage may have been leaking, but not sure if that could cause that much oil spray?
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I just changed the oil in the 04 GLS. It looks like the intercooler is leaking at the bottom hose. It does leave marks on the garage floor. Also I may have rear main seal leak too.
The car has 45K on it
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So I just don't have any luck with anything turbo related. Last time it was my intercooler that went out. Now the passenger side intercooler tube keeps popping off and the damn clamp is broken so I can't tighten back up to even get me to the damn truck stop. I guess it could be worse...it could be late at night and raining...oh what, it is.
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Seems my oil was leaking from my oil filter. I recently changed the oil a month ago but it didn't leak until a few days ago. I used a mobile 1 filter. I read that some people have issues with other filters other than motorcraft sometimes leak. I changed it with a motorcraft and it isnt leaking anymore. Could have just been a bad seal on the mobile 1..not sure
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My 01 excursion is leaking refrigerant. Added UV dye, and still can't find leak. It takes about 5-7 days to lose charge.
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I'm going to try the lucas solution to see if it will clear this up- but i don't drive it enough yet to really work it in.... I know the redhead solution seems to be what I should just go to- but I wouldn't mind replacing the gasket if there is one to see if that works...or maybe its not really from the gasket?
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So my wife nailed a small spike buck and he when up under the truck. On his way back, his antlers hit the intercooler. One side tube was collapsed and the other collapsed but tore open. Has to repair one the tubes and, if so, with what. I was thinking I could pull the dent out with a pick and then put some sort of epoxy over it.
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My 2000 Ex, v10, 194,000 miles, requires a new stabilizer shock and the shocks all the way around appear to be leaking. Any recommendations for new shocks? The vehicle receives heavy off-road use as well as towing a three horse trailer through mountainous terrain.
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I believe my rear AC lines in my 2003 EB V10 X pooped the bed on me today and Ford wants 3K to fix. I'm wondering if I could fix it my self. The leak was a bright green color so I'm assuming it was 134 or what ever in in the AC. The leak is right behind the passenger side of the motor just a little lower than the head. The dealer wants to replace almost everything for 3k but they don't want to budge on just repairing the broken line.
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Ac is leaking where the 2 lines go into the condenser. I went to Ford and bought OEM o-rings thinking it would be an easy fix. HA! New o-rings were put in by a mom and pop garage. Still leaking. Guy said it wasn't, but with my uv light I could clearly see the dye. Went to a recommended guy. He took it apart, cleaned the hoses where the o-rings sit. They were kinda dirty from leakage and stuff so he cleaned them up with a wire brush and 2000 grit.
Recharged, and we both looked with his huge uv light. Bad condenser, drivers side lit up like a night light. Replaced the condenser with an aftermarket condenser. Recharged, STILL LEAKING from where the hoses go into the condenser. Vacuumed down the system... Removed hoses, checked o-ring fit. They are snug on the hoses and have some resistance when plunging the hoses back in. What gives? I'm 360.00 into this this week...
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I have a very small oil leak that looks to be just above the starter in the passenger side of my Excursion. It never puddles but I can see it is a little wet and oily in the area. I smell it once in a while burning off of the exhaust but again very rarely and minor. It's a $4000 truck and has plenty of rust underneath and I have no intention of pulling the heads to replace a gasket if that is where it's coming from.
Just wondering if there is a likely culprit known in this area. I know I've seen reference to such a leak somewhere but I can't find any threads on it quickly. If it's a head basket, I assume it would be losing anti freeze more than oil, but where I can look? I am not above using some sort of surface putty or stop leak type of thing if it's got a chance of stopping it for a year.
I also am getting ready to pull off the passenger side exhaust manifold to replace the gasket and just can't wait to see how many studs have broken or will break off. I have until spring (camping season) to get it done and don't really ever need to drive it, so I have time when its not too cold in Wisconsin.
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Well, the ac in my truck has been less than exciting since I've owned it and its time to address it before another trip.
I crawled under last night to explore the Ac clutch air gap and found that the shaft seal is leaking and clutch is grooved pretty bad and covered in oil.
I'm thinking it's time for a compressor, clutch, orifice tube, expansion valve and reciever/dryer. Does that about sum it up? I haven't messed with AC systems much outside of my simple jeep system that was as easy as two seals and recharge in my garage to fix it.
Do I need to flush the lines out? Should I do that at all? Motor craft worth the cost over something like four seasons? Its almost twice the cost but in the end if something goes I'm further downstream after freon etc to charge it and the possible shop charge if I pay to have to done.
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Noticed some spotting in front of the house, and saw some leaking coming from the driver side near the axle. I'm guessing it's the axle seal leaking. I recently switched in to 4x4 about a week ago, shortly after that I noticed the leak. I have a trip to San Antonio coming up in the middle of Feb, about a 650 mile round trip. Can I continue with the plans and get it fixed afterwards?
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About a month after replacing the oil cooler and welding the egr cooler, I randomly got a "low oil pressure" message pop up on the dash. I checked my oil level when I got home and it was full so I assumed it was just the oil sending switch went bad. A couple days go by and I noticed a substantial puddle of oil under my truck so I popped the hood and the entire top passenger side of the engine was soaked in oil.
I assumed it was the inlet turbo oil gasket because the turbo pressure wouldn't go above half, but after replacing it the leak was still going strong. It turns out that all of that oil was spraying out of my intercooler boot at the front of the turbo. I ordered a new kit and replaced all the boots and pipes and got her running.
While driving around the block the turbo sounded like it was being smothered and wouldn't engage. 30 seconds later the truck went into limp mode. From what I've read it can be solved with a ccv mod but i don't think that will solve as much oil as I'm experiencing, however I could be wrong. Could this be a blown turbo seal or maybe the head gaskets?
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I didn't realize the 6.7 had two places that you need to monitor your coolant level. I've kept an eye on my coolant reservoir for the rad due to radiator failures reported but just today noticed there was another one for the intercooler. Mine was quite low. I'm sure most of you knew it was there but for those that didn't, keep that baby topped up I can't imagine having a hot intercooler is good.
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I have a 2000 Excursion and it appears the AC lines going into the condenser are leaking. I had a local shop replace them, vac and recharge the system for 96.00. The ac was never really cold, and he used a vac pump and gauges to recharge. He said he thought there was enough refrig in the system for me. I got tired of just cold air so I put a small bomb in the system tonight and woah, I had ice cold air again. I noticed that where he replaced the O-rings, it appeared to be oily again! I went to a friends house and he as the glasses and UV light and we could see the dye around the connections where the hoses bolt to the condenser. We cleaned em off with brake cleaner and will recheck tomorrow afternoon. How odd is it to have the O-rings replaced and then have it leak again? I know he did not use OEM O-rings. I do not think its the condenser, we can only see the die on the fitting and around the flange of the hoses.it is easy enough to replace the condenser and it is not labor intensive. I called the shop and he said it would be about 25.00 plus a recharge but he doesn't know its leaking AGAIN. Should I go and replace the condenser as well? This image doesn't show the lightly wetness around the flanges.... but here it is.
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This guy started as a slow leak. Now leaks down entire coolant res whether engine is running.or not. Appears the connection to the rest leg isn't sealed. Not sure if available from factory, or if I should cut it out and replace with barbed tee and hose clamps. That's my inclination. Not a ton of room to work with. I think it's an excursion specific thing, from pics I don't think super duty has a t there. Guessing it's where rear coolant line tees off?
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I successfully replaced the radiator on my 2003 Ford excursion (LMD, V10, gas). I filled her up with coolant and started her and turned on the air full blast.
Noticed though that she is now leaking somewhere between the engine and the transmission pan.Where and what to check?
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I have a windshield washer fluid leak. It's leaking onto the passenger side floor under the dash. Any have a good place to start looking or how to access the area it might be leaking at?
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'03 Ex. 6.0 Diesel 160k miles.
I have a power steering box leak that came on suddenly. The leak is coming from around the pittman arm shaft... and it is pouring out. It's not under pressure, it's just running out and running down the pittman arm.
I've never seen a steering box leak as bad as this is. I've checked the hoses and they all appear dry. Is this common? Can the seal be changed in the truck or should I be looking at changing the steering box?
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I bought a 2002 Limited EX, 164K on a 7.3 diesel, its been a California truck its whole life, but still has some "rust" on it... I'm sure it can mostly be wiped away with a rag and some solvent . I mostly bought this vehicle to tow my track car around (1993 Mazda RX7) and so my friends can be comfortable while I drag them all over to be my pit crew - the rear captains chairs are a sweet feature.
Unfortunately this is the only picture I have right now... At the pump...
First things to address were the EBPS and EBPS tube, replaced those today... And the HPOP is leaking a bit from one of the lines I think, I ordered some gaskets and whatnot from Riffraff and will address that next weekend.
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