Ford Super Duty (1999-2016) :: Huge Oil Leak From Top Rear Of Motor Not ICP


Nov 24, 2015

I got to work I parker her on the 6th floor of the parking garage. While unloading I smelt oil (but didn't act on it due to me running late) so I walked away towards the elevators. Forgot something from the truck and once turned back towards the truck noticed a MASSIVE oil spill underneath. Easily 2-4 qts ALL Over. Also had a trail of oil ALL the way down 6 floors out to the street. Truck had little to no oil left in the motor.

Truck runs/ran fine, numbers for ICP and HPOP all normal. Truck will still start fine and run fine. No codes, no surging, no rough idle nothing odd other than a MASSIVE and almost instant oil leaking once started.

About a week before this happened I changed the ICP and pigtail. I understand I used a cheaper version of it, and it just might be the ICP, but I stuck my hand back there, and felt just a little oil (im guessing residual from the previous faulty one) After I changed the ICP I noticed I will had oil leaking from somewhere. Is it possible that I just finally blew out what was still leaking?

I have an early 04 so 03 motor. Seems like no real wet oil spots before the turbo area. I'm planning on tearing her down friday, but would like to know really what to focus on. I thought the pressure switch, but specifically looked there while it was running. Oil is traveling from where the ICP is located (roughly) left (Driver side mostly) but will get some on right (Passenger side) of bell housing.

I tried looking under turbo and didnt see much wet under there. I can't imagine the ICP i just installed could be blown out and dumping THAT much oil. Within 10 seconds it's dripping heavy, within a minute of running there is a football size puddle on the ground. Will drip for another few minutes after shutoff.

I thought of oil filter and pressure sender but like I said couldn't see any wet pools of oil. What else under the turbo area could leak THAT much oil so quickly?

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Does this sound like a typical hub seal issue? Excuse my ignorance since I haven't had the rear hubs apart before but does the gear oil in the rear diff go into the axle tubes? I know the front tubes are dry but I didn't know if the rears are different. The amount of fluid on the brakes seems to be more than the little bit that is inside the hub. I need to pick up the parts and rent/purchase a couple of tools to replace the seal so I want to be as sure as possible that I'm on the right track...

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Here's what's happening:

I can have it on hot and be driving along, then it will start blowing cold air. I can move the temperature switch to cold then back to hot, and it'll start blowing hot air again.

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