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Discussion Starter #1
Am i screwed?

I was losing coolant, but could not figure out where from. Today, fired it up just long enough to pull in the garage and ten I noticed black water on the ground. Got under the truck and coolant was dripping from the exhaust. Could that just be the EGR cooler, or are my head gaskets done?
 

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Discussion Starter #2
Also, it had been smoking under load, and tested the FICM. FICM drops to 42 v when running. So assumed that was my smoking issue because smoke was always black, never white.
 

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If it's that bad, most likely the egr cooler. I'm surprised you didn't mention blowing white smoke so thick you can't see through it. Usually blown head gaskets send coolant out the puke jug on the firewall. You'll see white powder looking streaks across the jug.
 

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sounds like the egr cooler dont do any driving and get it replaced or deleted asap and fix your ficm too....
 

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Discussion Starter #5
Nope. No white smoke, no puking. Some days it would lose coolant and some days it would not.

Only black smoke, but again, FICM tested bad. So that sort of sums that one up.

Here's how this whole thing sort of started... When I first noticed problems anyway.

Got off the freeway one day. Truck had no power, was black smoking and throwing the EGR code. Limped it home pulled EGR valve. Very clogged up. Inside intake was dry. Cleaned it, put it back in, but did not replace the O rings. still was black smoking though, so I decided to replace the EGR valve. Still black smoking. Didn't really plan on EGR and FICM at the same time!!

So anyway, when I went back in to replace the EGR, just 2 days later it was a fairly wet in there, whereas 2 days before, it was dry. figured maybe EGR valve o-rings to blame since i had not replaced them.

Decided to pull the EGR valve again today, drier inside than before. Why would it get drier? Carbon was not "wet" more like "barely damp" and sort of flaky. would flake off when you touch it. However the valve did not move freely, and was actually stuck. Partially open stuck. Cleaned it and moves freely again.

Not sure where to go with all of this.
 

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Sounds like EGR cooler... If the truck looses coolant its gotta go somewhere.

Have you been watching your oil temp? That should have been a sign to prevent egr cooler failure...

I would say in most cases blown head gaskets will not make coolant pour out of the exhaust, egr cooler will though.
 

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Discussion Starter #7
That's what's weird also. I never get further than 5 to 6 degrees off. Typically unloaded at 65mph on flat ground I run a consistent 5* difference.
 

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Discussion Starter #8
I have a BPD egr cooler here at the house, but they give you no gaskets whatsoever. anyone have a list of required gaskets needed to complete that job?
 

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I have seen egr coolers fail with a good oil cooler, just rare...

You'll need intake manifold gaskets and the egr cooler gasket set. You can get them from ford, I don't have the part numbers here sorry
 

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Unless they are messed up the gaskets are reusable.
 
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