Excessive coolant usage and no smoke - help needed - Ford Powerstroke Diesel Forum
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Old 02-10-2011, 06:37 PM
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Excessive coolant usage and no smoke - help needed

Hey guys, this truck is really perplexing me. It came in for lack of cabin heat and coolant consumption+overheating engine. The trigger got pulled too early and I replaced the headgaskets and studded it. It's back now and the coolant level drops about a litre per hour of idling. There is NO smoke and the tailpipes are dry (DPF delete done as well). I simply cannot understand how a truck goes through this much coolant with no external leaks whatsoever and no smoke. It's an 06/07 build date 6.4. If anyone's seen this or has any tips/pointers let me know, this thing is killing me.
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Old 02-11-2011, 08:36 PM
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is the heater cores in the cabs on these or outside? My dodges was inside and could leak coolent into the cab
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Old 02-11-2011, 08:49 PM
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do you have notice of coolant around the clear tank? do you have an egr delete? could be coming from the egr coolers. it has to be going somewhere does it have a grayish smoke coming from the exhaust?
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Old 02-12-2011, 05:42 PM
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i would say egr or cavitation in the front cover from water pump, check the oil.
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Old 02-12-2011, 06:32 PM
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cavitated front cover. how is your oil level?

if you find a front cover gone out it might be wise to put an oil cooler in it. all that aluminum has gone somewhere

Last edited by sinner6.0L; 02-12-2011 at 06:35 PM.
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Old 10-21-2011, 07:37 PM
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Sorry it took so long to reply. The front cover had eroded badly, leaking coolant into the oil, right by the cam cavity.

New front cover and all is well, common issue I now know!
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Old 10-24-2011, 07:53 AM
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Quote:
Originally Posted by clys View Post
Sorry it took so long to reply. The front cover had eroded badly, leaking coolant into the oil, right by the cam cavity.

New front cover and all is well, common issue I now know!
How hard is the front cover to replace? How much did it cost? I wonder if there is a way to solve this problem...
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Old 10-24-2011, 08:00 AM
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Took about an hour with the cab off. I'd say 6 hours should be plenty with can on though.
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Old 10-26-2011, 07:13 PM
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Quote:
Originally Posted by 04hdfatboy View Post
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.
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Old 10-27-2011, 06:30 AM
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Quote:
Originally Posted by PowerstrokeTech82787 View Post
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.
Hey your back! Thanks for the info
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