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Join Date: Jul 2009
Location: Jefferson, Ga
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I believe there was a TSB that addressed repeat failures of the radiator on a 6.4l and said the problem could be result of the thermostats.
09-23-1 6.4L DIESEL ENGINES - REPEAT RADIATOR LEAK - BUILT ON OR BEFORE 9/14/2009
Publication Date: November 9, 2009
FORD: 2008-2010 F-Super Duty
Some 2008-2010 F-Super Duty vehicles built on or before 9/14/2009 and equipped with a 6.4L diesel engine may exhibit repeat radiator leaks due to malfunctioning (hyper-extended) high temperature thermostats.
Follow the Service Procedure steps to correct the condition.
Verify the coolant leak is from the radiator, refer to pin point test (PPT) A found in the Workshop Manual (WSM), Section 303-03.
Verify the venturi tee is installed.
If installed, confirm it is installed correctly (note - orientation direction on part). Refer to applicable Field Service Action (FSA) for vehicle built on or before 5/15/2008.
If not installed, install per applicable FSA on vehicles built on or before 5/15/2008.
Prepare the vehicle for a test drive.
If the coolant leak at the radiator is large enough to cause an unsafe test drive or potential for engine/vehicle damage, proceed to Step 5.
Before driving the vehicle confirm the coolant level is at minimum level or above in the degas bottle. If required add 50/50 mix to coolant bottle.
Test Drive - use an Integrated Diagnostic System (IDS) or equivalent and monitor engine oil temperature (EOT) and engine coolant temperature (ECT) parameter identifiers (PIDS).
With EOT at 195 °F (91 °C) drive on the highway unloaded at 55-70 MPH (89-113 Km/h) constant speed to observe EOT and ECT temp.
Test results/next steps:
If EOT is less than 8 °F (4.4 °C) higher than ECT, and the coolant temp fluctuates roughly 5 °F (2.7 °C) - the thermostats are okay and do not need to be replaced. Replace just the radiator. Refer to WSM, Section 303-03 (Engine Cooling).
If EOT exceeds ECT by greater than 8 °F (4.4 °C) or if the ECT readings fluctuate 10 to 12 °F (5.55-6.66 °C) roughly every 30 seconds - replace both thermostats and radiator. Refer to WSM, Section 303-03 (Engine Cooling).
If vehicle is not drivable and the coolant leak is found to be from the radiator, remove and replace both thermostats and radiator. Refer to WSM, Section 303-03 for both radiator and thermostat removal procedure and approved cooling system draining, filling and bleeding procedures.
PART NUMBER PART NAME
8C3Z-8575-D Thermostat Assembly
8C3Z-8009-B Radiator Assembly
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092301A 2008-2010 F-Super Duty 6.4L: Pressure Test Cooling System, Road Test, Monitor PIDS, Replace The Radiator (Do Not Use With Any Other Labor Operations) 3.0 Hrs.
092301B 2008-2010 F-Super Duty 6.4L: Pressure Test Cooling System, Road Test, Monitor PIDS, Replace The Radiator, And Thermostats (Do Not Use With Any Other Labor Operations) 3.8 Hrs.
BASIC PART NO. CONDITION CODE