Originally Posted by 04hdfatboy
How hard is the front cover to replace? How much did it cost? I wonder if there is a way to solve this problem...
Theyre not too bad, just pull the radiator etc out of the way, you dont need to suck the a/c down i bend the condenser out of the way so i can sit on the front bumper and from there i remove the fan and hub, the plastic hose that runs up top thats brittle be careful with it because its a PITA to change, i remove the vertical egr cooler, i inspect the coolers at this time to make sure all is well, and then the rest is the 10mm bolts pull the crank pulley i remove the oil pump its easier to remove and i lightly push the plastic coolant hose up slightly and walk the bottom of the front cover off then pull the top slowly until its free. Then i clean the face of the block with brake clean, rags, and a plastic wiz wheel.
I too have been wondering what causes it. This summer no lie I did at least 3 or 4 front covers/radiators water pumps and updated hoses with doubled O rings a day. Id guess its either poor quality in materials for the cover (when they look like a 12ga with 00 shot hit it id say poor quality in material), and hyper extended thermostats. The thermostat housing in a few were gone theres 2 prongs that the T stats "twist" into that were missing and the thermostats were just sitting at the bottom of the T stat housing. When they look bad, just like Sinner said replace the oil cooler because thats where the debris end up.