Intercooler - 04 Ex 6.0 - Ford Powerstroke Diesel Forum
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Old 08-12-2013, 05:13 PM Rookie

Join Date: Jan 2009
Location: NC Piedmont
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Intercooler - 04 Ex 6.0

Just had the oil cooler and high pressure oil pump replaced on my (176K miles) 4X4 '04 Excursion and when my wrench, Bob McDonald, [ ] tested it we heard a hissing from the front and no power from the turbo. The intercooler sprung a leak, Found that the rubber gasket had popped out of front and rear of the right lower plastic tank connection to the aluminum core.
I either hadn't noticed or heard of this problem but it was another chunk o' change from my wallet.
So far done: EGR bypass, ball joints, idler pulley, turbo rebuilt, tie rod, chrome running boards (rusted out on right rear), heater core "Y" hose and roof rack cross bar. Haven't added a programmed chip so I don't have any issues with the head bolts or gaskets, yet.
I will probably be putting it on the block to upgrade my ride. Check out:
2004 Ford Excursion
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