Where is my coolant going? - Ford Powerstroke Diesel Forum
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post #1 of 22 Old 09-04-2019, 10:57 AM Thread Starter
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Where is my coolant going?

Over the last several months, I have had to add about 1 gallon of coolant every few weeks. I noticed residue at the degas bottle cap and bought a new cap from ford. Nothing changed. Engine runs perfect. Engine studded 40k ago. Bulletproof diesel EGR cooler installed along with new oil cooler. Last week, I pulled my 30ft toy hauler to a MX track and back. Every 20 minutes I had to stop and let it cool down from overheating. I would fill with coolant and continue. It seems that the coolant is going first, then overheating instead of losing coolant due to overheating. In all, I put over 20 gallons of water in the system in less than two hours of driving. During this driving, the engine ran perfectly. Wife was following me on her motorcycle and noticed nothing coming from the truck. I friend of mine was driving behind her and noticed nothing. Where is the water going? I had steam coming from the degas bottle each time I stopped, but no signs of that much water anywhere. Detached trailer once back at my house and drove truck to airport for a trip with no issues. Thank you for your help.
Wife saw nothing driving behind.
No water on windshield
No water on underside of truck
No water on Toyhauler
No water in engine oil
Runs perfectly
No white smoke
Normal water at front and rear evaporator points(Excursion)
Water loss present during normal driving, but much worse with trailer.

Questioning, Head Gasket? EGR Cooler? Clogged Catalytic Converter? Failing fan clutch? Underperforming water pump?
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post #2 of 22 Old 09-04-2019, 11:21 AM
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Well, the good news is, if you added that much volume to the system, you should be able to spot the external leak pretty easily. The bad news is, you can't find an external leak...

Time to pressure test the coolant system to see if it holds and to see if you can force an external leak to show itself.

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Originally Posted by wchapman View Post
Questioning, Head Gasket? EGR Cooler? Clogged Catalytic Converter? Failing fan clutch? Underperforming water pump?
I'd say first 2 is your best bet (unfortunately the odds are stacked against you that it's the BPD EGR cooler).

-jokester

2005 F350 CCLB FX4 Lariat
SCT SF3 - Currently running PHP 80hp Daily Driver Tune with Atlas 40 FICM Tune
Edge Insight CTS2 monitor
Edge EAS EGT probe
Edge EAS Fuel Pressure Sensor

Last edited by jokester00; 09-04-2019 at 11:25 AM.
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post #3 of 22 Old 09-04-2019, 11:47 AM Thread Starter
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Jokester- Thanks for the gentle delivery of telling me I have a large bill in my future. I will pressure check and get back to you. It has to be going somewhere.
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post #4 of 22 Old 09-04-2019, 12:00 PM
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I got a $80 pressure coolant checker from Harbor Freight. It has done well at finding leaks. I pressurize to 16 PSI and wait. I could see the leaks. Sometimes they show up right away, sometimes I need to use some soap / water solution for a bubble checker to spot a micro leak, and other times it shows up right away. My truck has checked out fine, but my car has had leaks a couple of times, including once I found three different leaks in test with the checker.

I hope you find a leak this way versus a more expensive routes.
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2005 F250, 189,000 Miles
Bullet Proof HD Oil Cooler w/ Cold Weather Kit, Bullet Proof EGR, Bulletproof Water Pump, 7.3 Fan Clutch
Airlift 5k Airbags and Wireless Air
Edge CTS w/ EGT probe and Fuel Pressure Sensor.
15 MPG slick; 10 MPG towing 11k fifth wheel
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post #5 of 22 Old 09-04-2019, 05:36 PM
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Assuming its not in the oil, or tranny fluid, you must be burning it......Just a heads up, if its that bad you might wake up one morning to a hydro locked motor
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post #6 of 22 Old 09-05-2019, 06:17 AM Thread Starter
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I agree, but can’t imagine that much being burned with no white smoke. Will pressure and bubble test.
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post #7 of 22 Old 09-05-2019, 06:26 AM
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If what's listed above does not work, park nose down overnight and pull the EGR valve looking for coolant, sludge on the EGR valve, or a steam cleaned EGR valve. That will show a leaking EGR.
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2005 F250, 189,000 Miles
Bullet Proof HD Oil Cooler w/ Cold Weather Kit, Bullet Proof EGR, Bulletproof Water Pump, 7.3 Fan Clutch
Airlift 5k Airbags and Wireless Air
Edge CTS w/ EGT probe and Fuel Pressure Sensor.
15 MPG slick; 10 MPG towing 11k fifth wheel
Ravelco

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post #8 of 22 Old 09-05-2019, 09:45 AM Thread Starter
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I’ve done this with nose flat/up position and noticed the bottom of the casing below egr damp. Should this be chalky/dry? I will get it hot and pull EGR nose down. Thanks.
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post #9 of 22 Old 09-05-2019, 10:09 AM
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Quote:
Originally Posted by wchapman View Post
Iíve done this with nose flat/up position and noticed the bottom of the casing below egr damp. Should this be chalky/dry? I will get it hot and pull EGR nose down. Thanks.
Black chalky carbon would be fine. If the EGR leaks, it'll make it a black sludge or steam clean it. Nose down would have the coolant pool there if it leaking out the EGR.

2005 F250, 189,000 Miles
Bullet Proof HD Oil Cooler w/ Cold Weather Kit, Bullet Proof EGR, Bulletproof Water Pump, 7.3 Fan Clutch
Airlift 5k Airbags and Wireless Air
Edge CTS w/ EGT probe and Fuel Pressure Sensor.
15 MPG slick; 10 MPG towing 11k fifth wheel
Ravelco

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post #10 of 22 Old 09-05-2019, 11:57 AM
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I'll throw this in here too...


-jokester

2005 F350 CCLB FX4 Lariat
SCT SF3 - Currently running PHP 80hp Daily Driver Tune with Atlas 40 FICM Tune
Edge Insight CTS2 monitor
Edge EAS EGT probe
Edge EAS Fuel Pressure Sensor
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