CONFIRMED: Combustion Gases in Coolant!! - Ford Powerstroke Diesel Forum
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  #1  
Old 01-13-2013, 09:34 AM
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CONFIRMED: Combustion Gases in Coolant!!

I've had my '05 F350 for almost 2 years now. Since buying it, we've put almost 40,000 miles on it. I talked with the previous owner and he confirmed that at around 100k, the head gaskets were changed (w/ TTY bolts), EGR was deleted, oil cooler was replaced, etc.

Before buying the truck, I rigged up a cooling system pressure test and confirmed that the truck did not have any typical 6.0 issues. Shortly after buying the truck, I added gauges to monitor everything and have never had any signs of any problems; also no puking from the degas either. Well, that has now changed. We went to SC for Christmas and took the truck. Upon returning home I smelled coolant when we parked and popped the hood and saw that the degas bottle cap had let some coolant out. Since then, I've seen it wet around the cap fairly consistently. I've also heard air bubbles moving around the cooling system once after shutting it down.

Today, I picked up a combustion gas detector and ran the test. Of course, the fluid turned green/yellow, confirming combustion gases in the cooling system.

Interestingly enough, the truck runs fine, starts fine, has great power and is still getting ~20mpg at 65mph. There is no change in temperatures, nothing out of the ordinary - The degas puking was the ONLY symptom that anything was up.

From the reading that I've done, I'm preparing to do this job myself. I'm fully capable of doing it, I'm just a little fuzzy on exactly which parts I need. I'm trying to put together a parts total so that I can figure out exactly how much this is all going to cost...

Here's my parts list so far:

OEM Gaskets (which size 18 or 20?)
ARP head studs
Oil cooler
HPOP screen (since we're in there anyway)
Standpipes and dummy plugs (to ensure they're in good shape and newer style)

Obviously, I'll have the heads checked out for cracks, etc.

Can someone give me an idea of things I'm missing? Also, best place for prices?


HELP!

Last edited by Dante04SRT; 01-13-2013 at 09:41 AM.
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Old 01-13-2013, 11:45 AM
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well your 05 was originally equipped with 18mm heads but if the heads were off once is there a chance one was changed? If you are certain no heads were changed you'll need 18mm headgaskets.

As for the oil cooler screen it comes with the oil cooler kit. Standpipes come with a ford headgasket kit but you'll have to get dummy plugs on your own.

pick up a turbo drain tube, egr cooler gasket kit, intake gaskets, rocker box gaskets, glow plug harnesses(if your sending the heads out they'll want everything removed), 8 injector o-ring kits.

it would be a good idea to change all of your exhaust manifold bolts and add gaskets there too. also the dipstick needs removed and there is an o-ring on that.
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Old 01-13-2013, 11:48 AM
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6.0 Head Stud Part List.
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Old 01-13-2013, 11:58 AM
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Thanks reliob lol.

Well since I always get asked what parts I would recommend and where to get them as well as prices and part numbers I figured I would compile a list of parts for people to choose from for their head gasket and stud jobs.



ARP Head Studs: 250-4202 - Let me know if I can help you out with these, stealth automotive $439

OEM Oil Cooler Rebuild kit: 3C3Z 6A642 CA- Order from sunrisefordparts.com $269.43 shipped

OR

BPD Remote Oil Cooler Kit - Price varies depending on what options you choose.

KEEP IN MIND THAT THE IPR Gen 2 EGR delete is NOT compatible with the BPD oil cooler kit.

IPR Gen 2 EGR delete kit: SKU: EGD-60GEN2B- iprresearch.com $259.99 + shipping

IPR High Flow Coolant Filter: iprresearch.com $249.00 + shipping

2003 Glow Plugs (SHORT) need 8: 3C3Z 12A342 AA - sunrisefordparts.com $13.20 ea. $105.60 total
2004-2007 Glow Plugs (LONG) need 8: 4C3Z 12A342 AA - sunrisefordparts.com $11.27 ea. $90.16 total

2003 - 2004
Glowplug buss bar right side: 3C3Z 12A690 BA - sunrisefordparts.com $40.80
Glowplug buss bar left side: 3C3Z 12A690 AA - sunrisefordparts.com $40.80

2004.5 - 2007
Glowplug harness left side: 4C2Z 12A690 BA- sunrisefordparts.com $40.80
Glowplug harness right side: 4C2Z 12A690 AB- sunrisefordparts.com $40.80

Updated Turbo drain tube: 6C3Z 9T515 A - sunrisefordparts.com $24.37
Updated Turbo Oil feed: 3C3Z 9T516 A - sunrisefordparts.com $87.50

Thermostat: 4C4Z 8575 AA - sunrisefordparts.com $28.60

6.4 Banjo bolts: w302472 Need 2 - sunrisefordparts.com $10.50
6.4 banjo bolt washers: w303659 need 4 - sunrisefordparts.com $3.60

Main drive belt: jk8 1331 a - sunrisefordparts.com $49.82
Secondary drive belt: jk6 664 a - sunrisefordparts.com $25.34

Updated dummy plugs need 2: w302908 - sunrisefordparts.com $12.30 ea $24.60 total.
Updated standpipes need 2 (2003-2004.25): 3C3Z 6N853 BA - sunrisefordparts.com $51.60 ec $103.20 total. Not sure if headgaskets for the 03 come with the standpipe or not?? Checking on this and will update when I get the proper information.
Updated Standpipes need 2 (2004.5-2007): 6E7Z 9A332 A - sunrisefordparts.com $45.60 ea $91.20 total. Keep in mind new head gaskets come with 1 standpipe with each head gasket.
There is also a "kit" that has both updated dummy plugs (2) and both updated standpipes (2): 6E7Z 9A332 B - sunrisefordparts.com $111.60

18mm OEM Head Gaskets: 3C3Z 6051 CB need 2 - sunrisefordparts.com $147.60 each, $295.20 total for both. Comes with new updated standpipe, new gasket and head locating dowels (each gasket has one of each and 10 TTY bolts).

20mm OEM Head gaskets: 6C3Z 6051 AA need 2 - sunrisefordparts.com $271.20, Comes with new updated standpipe, gasket TTY headbolts and head locating dowels. Sunrisefordparts.com*

DEPENDING on the MY of your truck you will either have 18mm or 20mm heads.
Build date before Jan 17, 2006 you have an uncommonized engine with 18mm heads and dowels.
Build date after Jan 17, 2006 you have a commonized engine with 20mm heads and dowels.

Water separator updated drain kit: 6e7z 9c082 a - sunrisefordparts.com $12.50

OEM Oil Filter: FL 2016 - sunrisefordparts.com $19.50
OEM OIL FILTER NOT NECESSARY IF YOU BUY THE BPD OIL COOLER KIT.

OEM Fuel Filter Kit: 3c3z 9n184 cb - sunrisefordparts.com $49.95

Exhaust manifold gaskets: 6c3z 9448 a need 2 - sunrisefordparts.com $21.22

CAC boots both hot and cold side. RIFFRAFFDIESEL.com I paid $140 shipped. If your cold side CAC (intercooler tube) is black plastic than upgrade to the metal one. 6c3z 6c640 aa sunrisefordparts.com $115.08

Injector o-ring kit: 3C3Z 9229 AA need 8 - sunrisefordparts.com $31.68 (if you send injectors to Jesse Warren you don’t need this part)*

Fleetgaurd Restore and Fleetgaurd Restore + cooling system chemical flushes. Can get at local big rig truck dealers (they can order it) usually around $23-$30 a gallon, need one gallon of each.

Zerex EC-1 Rated ELC fully formulated coolant, 1 case* buy it at NAPA Part number is ZXED-1 usually between $13-$20 a gallon times 6 in a case.

Rotella T6 full synthetic oil

I would also suggest updated ported rockers OR at the very least new plastic fulcrums for them.

For the rockers here is the Part numbers and prices.

Combination need 6 of these, 4C3Z 6564 AA - $52.80 each $316.80 total for all 6 @ sunrisefordparts.com

Single Intake rocker need 2 of these, 3C3Z 6564 BA - $44.40 each $88.80 total for both @ sunrisefordparts.com

Single Exhaust rocker need 2 of these, 3C3Z 6564 AB - $44.40 each $88.80 total for both @ sunrisefordparts.com

I would suggest push rods since it’s apart. 8c3z 6565 b need 16- sunrisefordparts.com $64.80

Depending on mileage it may be a good idea to replace the Roller Lifters.
Roller lifters with plastic guide and 4 lifters, need 4 of these sets: 8C3Z 6C329 A - sunrisefordparts.com $52.80 a set, $211.20 total

ARP Ultra Torque Lube 10oz bottle with brush*
ARP 100-9910 Ultra Torque Assembly Lubricant - 10 oz. Brush Top Container : Amazon.com : Automotive ARP 100-9910 Ultra Torque Assembly Lubricant - 10 oz. Brush Top Container : Amazon.com : Automotive

Fumoto quick drain valve for the oil pan F-111n
Fumoto F-111N Engine Oil Drain Valve : Amazon.com : Automotive Fumoto F-111N Engine Oil Drain Valve : Amazon.com : Automotive

Fumoto quick drain valves for the block plugs F-108N*
Fumoto F-108N Engine Oil Drain Valve : Amazon.com : Automotive Fumoto F-108N Engine Oil Drain Valve : Amazon.com : Automotive

Snap-on torque adapter tool for rear head bolt on driver side. SRD35 $55 + shipping

11/16 12pt 1/2” drive short socket for head stud nuts.
18mm 1/2” drive 6pt socket to remove head bolts.

Blue spring fuel pressure update: 3C3Z 9T517 AG - sunrisefordparts.com $57.60

Updated STC fitting for 2005-2007 trucks: 4C3Z 9B246 F $42 at sunrisefordparts.com

HPOP cover gasket: 3C3Z 6619 EA - sunrisefordparts.com $13.20

IPR screen update: 3C3Z 9H529 A - sunrisefordparts.com $30.00

IPR valve (2003-2004): 3C3Z 9C968 AA - sunrisefordparts.com $195.60
IPR valve if it needs replaced (2005-2007): 5C3Z 9C968 CA - sunrisefordparts.com $186.00 (can be found cheaper)

If doing head gaskets on a 2003 - 2004.25 I would suggest replacing the ICP sensor and pigtail as well while it is apart as it is buried under the turbo and it would be a quick swap while it is all apart. That and they are known to fail on these MY's.

ICP sensor (2003-2004): 3C3Z 9F838 EA - sunrisefordparts.com $114.00
ICP sensor (2004.5-2007): 4C3Z 9F838 A - sunrisefordparts.com $114.00
ICP sensor pigtail (also the same pigtail for the EBP sensor): 5C3Z 12224 A - sunrisefordparts.com $60.00

If you decide to replace the HPOP this is where I would get it (I got mine from here) it comes with the updated STC fitting as well as a new IPR valve and the HPOP (2005-2007 models come with IPR and STC fitting 2003-2004 only come with the pump).

2003-2004.5 HPOP: 3C3Z 9A543 AARM - sunrisefordparts.com has it for $564 +$150 core. Injectorwarehouse.com is $579.95 + $200 core charge.
HPOP-123X Ford Power Stroke High Pressure Oil Pump - Injector Warehouse

2005-2007 HPOP: 5C4Z 9A543 A - sunrisefordparts.com has it for $666.00 +$150 core for the pump only this place is $599.95 + $75 core charge and includes the updated STC fitting and new IPR valve with updated screen.
HPOP-122X Ford Power Stroke High Pressure Oil Pump - Injector Warehouse


If I forgot anything I will add it later lol.

Also here is a link to most of the parts/numbers anyone would ever need for their 6.0L incase I missed something that someone might need or want.

6.0 Parts List By FORD?INTERNATIONAL

And here is a link to my build thread showing how it is possible for one person to tackle this job in their driveway, by themselves, with limited tools AND wearing only FILPPY FLOPPIES, shorts and a tee shirt!

She's under the knife, My build thread. Lots' Pics.
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Old 01-13-2013, 12:08 PM
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Excellent list; I hadn't seen that before!

My original plan (cost related) was to use an OEM oil cooler - Realizing of course that the best option is the BPD kit, is it foolish to use the OEM cooler?
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Old 01-13-2013, 12:14 PM
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Do you plan on keeping the truck for a LONG time?? If so then yes spend the money now and get the BPD kit.

Here's the deal Brian. I just did my head gaskets and studs myself in my driveway in September only to have what was a good oil cooler with delta's of 3-5* max spike to over 17* when I reassembled and added coolant. I decided at that point that if I had to tear back into the truck again that I didn't want it to be for a stupid azz oil cooler failure. I also plan on driving my truck til the wheels fall off of it and I also just want to enjoy my truck now. So after having done all that work only to find out I needed to do ANOTHER oil cooler swap I had enough and did what I said I would never do lol. I bought the BPD kit.
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Old 01-13-2013, 12:50 PM
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Did you replace your cooler when you did your head gaskets?

I did a coolant flush in June 2011 and delta was around 10* afterwards. My current delta (18 months; 35,000 miles later) is around 16-18* so either way, I'd be replacing the cooler. I just don't know if I could justify the $2000+ cost for a BPD one right now.

Last edited by Dante04SRT; 01-13-2013 at 12:55 PM.
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Old 01-13-2013, 12:59 PM
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No I had a ruptured oil cooler in July of 2011 and I replaced it then chemical flushed the chit out of it with Restore and VC-9. Installed my coolant filter and Cat EC-1 rated ELC and called it good. Then my head gaskets blew in February of 2012 and kept puking coolant out of the degas bottle like it was it's job and I got tired of spending $15-$20 on a gallon of coolant each time so I filled it up with water and just plugged it in at night during the rest of the Winter.

Come May I flushed the cooling system with Restore and VC-9 again and added 3 gallons of Zerex EC-1 rated ELC and topped off with tap water. Monitored my deltas and never saw a rise more than 5* EVER. So I wasn't worried about changing the cooler when I did studs and gaskets. So I did all the work and filled it up with tap water for the initial start and test drive and all was still good with 3-5* spreads. I then drained and just flushed a couple of times with distilled water and then added my coolant and called it a night (also note that while it was apart I had cleaned the heater core and back flushed it as well then sucked it out with a shop vac). Got in the truck the next morning and left and was monitoring my deltas and what do you know?? 17-19* spread. At that point I was pissed so I got on the phone with BPD and started making arrangements to purchase their kit. I still haven't installed it lol it's sitting in my bedroom right now but I will install it when the weather breaks and then I will forever be done with OEM oil cooler problems on my truck.

Also note that this would be the 4th OEM oil cooler failure in my truck. So I enough is enough.
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