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'04 Excursion 6.0 oil problem
Greetings to all! I have searched the forums and found similar issues but nothing that exactly matches. Some may find this interesting, and I am in need of suggestions.
I changed the oil as I have done dozens of times. Factory oil filter cap and factory oil filter always. I wish to stress this. Both are Motorcraft parts for the 6.0. I installed the new, oiled, O-ring on the cap, new filter snapped in, ready to go. I ran the cap down by hand until the O-ring touched the housing. I then used my torque wrench to finish the install and torqued to final spec. Topped the oil off at 15 quarts and called it an evening.
When driving to work the next day I got maybe 5-6 miles from home and I looked in the outside mirror and saw nothing but grey smoke. I checked the oil pressure gauge and it was fine, then it fluttered and the truck died. I coasted to the side and when I popped the hood it was coated underneath with oil. The back of the engine and all the way to the rear bumper as well as the back glass and doors (again it is an Excursion) were covered in oil. It looked like an oil bomb had gone off.
Flatbed home and I quickly cleaned the oil from the painted surfaces and then took another car to work. After getting home I cleaned the engine and underside as best as I could then began looking around. Obviously it ran fine before the oil change so I started with the cap and filter. When I took the cap off (again, factory Motorcraft cap and filter) the top of the stalk that holds the spring and the disk were inside the filter.
The two plastic "fingers" that retain the disk and center button were broken and I found them inside the housing. I pieced together the two broken fingers with the body they were once a part of to ensure that nothing had entered the oil system. I couldn't find anything else that was a miss. I cleaned the engine bay some more, cleaned the underside some more, replaced the stalk, cap, and filter with factory parts, topped off the oil (it lost most but not all) and started it up. It took a lot longer to start but it did fire and idled. I drove it around the yard and got it up to temp then started looking around. With a fresh piece of cardboard underneath there was a few drops of oil towards the driver's rear side but it could have been residual from the "bomb" and clean-up.
So I let it sit overnight and started it with another clean piece of cardboard underneath and it has a few oil spots underneath, mainly on the driver's side rear. It still takes a lot longer to start and until I get some advice on where the massive amount of oil came from I am afraid to drive it. It has had all of the reliability mods done (EGR delete, studs, heads milled) and it has a SCT tuner. No lights, codes, nothing. ICP on valve cover and looks intact.
Any thoughts as to where all of the oil came from? Did I waste my HPOP? As much as the 6.0 gets a bad rap this one until this point has been good to my family, and even with that said it was something I guess I did when installing the new filter but I don't know what. Speaking of which, it is my family hauler so any advice given is greatly appreciated. I spin my own wrenches and if I could get a clear picture as to where the oil came from I will take off and see what I can find.
An inspection mirror and about an hour's worth of looking yielded nothing. I might have to start removing things in order to find the problem hence the reason for posting. I just don't want to start blindly removing things that may be unnecessary. Thanks again