coolant loss—6.0l tsb 08-11-3€¦ · 08/01/2009  · coolant loss—6.0l tsb 08-11-3 2003-2007...

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COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes TSB 08-3-7 to update the b. Install a pressure tester in-line with the Service Procedure. degas bottle hose using Rotunda 014-R1068 adapter. (Figure 1) ISSUE Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2008 E-Series vehicles, all equipped with a 6.0L engine, may exhibit: Coolant venting from the degas bottle cap No-crank/no-start Coolant leak White smoke from tail pipe Low coolant Lacks power overheat No cabin heat The conditions typically occur when operating the vehicle under a load such as trailer towing, uphill driving, or both. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Prior to making any repairs, verify the coolant level is not overfull. The new coolant fill level is at the “MIN” line of the degas bottle cold. Overfilled coolant levels will cause coolant to vent from the degas bottle cap. NOTE Figure 1 - Article 08-11-3 A FLOW CHART OF THIS PROCEDURE CAN BE FOUND AT THE END OF THE TSB. (FIGURES c. Pressurize the cooling system by using slow 9-11) and steady pump action on the tester pump handle. Quick or rapid pumps on the tester Complete All Steps In Order As Outlined handle may cause false readings. 1. Testing the degas bottle and pressure cap for Pressurize the system until the gauge proper operation of the pressure cap and its pressure levels off, between 12-18 psi seal to the degas bottle: (83-124 kPa). a. Do not remove the pressure cap. d. The degas cap should release between 12-18 psi (83-124 kPa) allowing the pressure to level off. NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information is available through Ford Motor Company’s on-line technical resources. Copyright 2008 Ford Motor Company Online Publication Date May 16, 2008 PAGE 1

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Page 1: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

COOLANT LOSS—6.0L TSB 08-11-3

2003-2007 F-Super DutyFORD:2004-2008 E-Series

2003-2005 Excursion

This article supersedes TSB 08-3-7 to update the b. Install a pressure tester in-line with theService Procedure. degas bottle hose using Rotunda 014-R1068

adapter. (Figure 1)ISSUESome 2003-2007 F-Super Duty, 2003-2005Excursion and 2004-2008 E-Series vehicles, allequipped with a 6.0L engine, may exhibit:

• Coolant venting from the degas bottle cap

• No-crank/no-start

• Coolant leak

• White smoke from tail pipe

• Low coolant

• Lacks power overheat

• No cabin heat

The conditions typically occur when operating thevehicle under a load such as trailer towing, uphilldriving, or both.

ACTIONFollow the Service Procedure steps to correct thecondition.

SERVICE PROCEDURE

Prior to making any repairs, verify the coolant levelis not overfull. The new coolant fill level is at the“MIN” line of the degas bottle cold. Overfilledcoolant levels will cause coolant to vent from thedegas bottle cap.

NOTEFigure 1 - Article 08-11-3A FLOW CHART OF THIS PROCEDURE CAN BE

FOUND AT THE END OF THE TSB. (FIGURES c. Pressurize the cooling system by using slow9-11) and steady pump action on the tester pump

handle. Quick or rapid pumps on the testerComplete All Steps In Order As Outlined handle may cause false readings.

1. Testing the degas bottle and pressure cap for Pressurize the system until the gaugeproper operation of the pressure cap and its pressure levels off, between 12-18 psiseal to the degas bottle: (83-124 kPa).

a. Do not remove the pressure cap. d. The degas cap should release between12-18 psi (83-124 kPa) allowing thepressure to level off.

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to dothe job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in propervehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact aFord, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentationdetermine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin(TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information isavailable through Ford Motor Company’s on-line technical resources.

Copyright 2008 Ford Motor Company Online Publication Date May 16, 2008 PAGE 1

Page 2: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

TSB 08-11-3 (Continued)

(1) If the degas cap releases with less b. Install cooler block-off tools (Figure2) andthan 12 psi (83 kPa), replace the cap. pressurize the EGR cooler to 30 psi (207

kPa). Fasten the inlet and outlet port(2) If degas cap was replaced, apply block-off plates using standard bolts, nuts

pressure and wait 30 seconds for and washers. (Figure 2)pressure to stabilize.

(3) If the gauge pressure drops:

(a) Apply soapy water around the capto find any leaks.

(b) Check the degas bottle fill neck lipfor nicks or cracks. Small nickscan be removed by light sandingwith fine emery cloth.

(c) Re-pressure test, if leaks are stillpresent replace the pressure cap ifnot already replaced in a previousstep.

(d) Re-pressurize the system and testagain, if leaks are still presentreplace the degas bottle, Refer toWSM, Section 303-03.

e. After verifying that the degas bottle,pressure cap and cooling system are ingood condition, proceed to Step 2.

2. EGR Cooler Leak Test On Vehicle:

a. Install RADKITPLUSA 078-00592 on thedegas tank.

b. Regulate shop air to 100 psi (690 kPa) andapply vacuum to cooling system until gauge Figure 2 - Article 08-11-3stops decreasing or 20 inches of vacuum isreached. (Degas bottle coolant level must c. Submerge the EGR cooler in water andbe set to “MIN” line with a cold engine to inspect for bubbles.allow sufficient space for vacuum.)

(1) If bubbles identify a leak, replace thec. Hold vacuum and allow vacuum to stabilize. EGR cooler and proceed to Step 4.

(1) If vacuum holds steady over 15 (2) If bubbles do not identify a leakminutes proceed to Step 5. proceed to Step 4 and re-install the

original EGR cooler.(2) If vacuum does not hold steady over

15 minutes proceed to Step 3. 4. Testing Oil Cooler:

3. EGR Cooler Leak Test Off Vehicle: a. Gain access to the top of the oil coolerfollowing WSM, Section 303-01C; only

a. Remove the EGR cooler from the engine necessary steps since the EGR cooler is outfollowing Workshop Manual (WSM), Section of the vehicle. The test can be performed303-08. without removing the entire oil cooler from

the engine.

PAGE 2

Page 3: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

TSB 08-11-3 (Continued)

b. Apply the RADKITPLUSA as shown. (Figure3) Regulate shop air to 100 psi (690 kPa)and apply vacuum to rear coolant portremoving all residual coolant. The oil coolermust be free of coolant. Residual coolantwill cause a false gauge reading.

c. Stop the flow of shop air once the residualcoolant has been removed.

d. With the RADKITPLUSA still attachedregulate shop air to 100 psi (690 kPa) andapply vacuum to rear coolant port. IfRADKITPLUSA gauge needle moves fromthe rest / full stop position (indicating

Figure 4 - Article 08-11-3vacuum), replace the oil cooler. (Figure 3)

b. Carefully release the cooling systempressure, leaving the tester in place.

c. Seal pressure bleed.

d. Drive the vehicle at wide open throttle(WOT) / high load / maximum boost.

e. Observe whether the cooling systempressure exceeds the holding pressure of12-18 psi (83-124 kPa) noted in Step 1.

f. Check for coolant venting through the degasbottle cap by listening for a hissing noise.

g. Observe ECT and EOT PID’s on IDSFigure 3 - Article 08-11-3 Datalogger. EOT maximum temperature

differential might occur at throttle tip-out.CAUTIONCOOLANT ENTERING ANY COMBUSTION 6. Road Test Evaluation:CHAMBER MAY CAUSE A HYDRO LOCK

Follow IDS PVT Datalogger instructions on screen.CONDITION. EVACUATE INTAKE PASSAGESAND COMBUSTION CHAMBERS OF ALL a. If EOT is within 25 degrees of the ECT andLIQUIDS USING A SUCTION DEVICE. REMOVE the cooling system pressure is less than theGLOW PLUGS (REFER TO WSM, SECTION holding pressure as noted in Step 1 proceed303-07B) TO ASSIST IN VENTING LIQUID FROM to Step 7.COMBUSTION CHAMBERS, BEFORE ENGINE ISSTARTED. b. If EOT exceeds ECT by 25 degrees at any

time during the test, replace the oil coolere. Re-assemble engine, fill the cooling system, and leak check the EGR cooler off vehicle

perform Step 5a - 5e and proceed to Step using procedure in Step 3. Repeat Step 56b. following oil cooler replacement.

5. Road Test Setup And Observations: NOTEDO NOT REPLACE HEAD GASKETS IF COOLINGa. Install the IDS PVT, or Rotunda PressureSYSTEM PRESSURE EXCEEDS DEGAS CAPAdapter Kit 014-00761, or equivalent.HOLDING PRESSURE WHEN EOT EXCEEDS ECT(Figure 4)BY 25 DEGREES.

PAGE 3

Page 4: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

TSB 08-11-3 (Continued)

c. If the cooling system pressure is greater b. Check the surface of the heads for flatnessthan the holding pressure noted in Step 1, and/or imperfections. Refer to WSM, Sectionand/or the degas bottle cap continuously 303-00 for the REVISED cylinder headvents when loading the engine and the EOT flatness measuring procedures.is within 25 degrees of the ECT, perform

c. Use the following revised head bolt torquePC/ED Cooling System Diagnostics for thesequence and specifications. (Figure 5)Vistronic Fan Clutch. If Vistronic Fan ClutchRefer to TSB 07-10-4 for cylinder headpasses or has been replaced continue toidentification.Step 8. If Vistronic Fan Clutch fails replace

the Vistronic Fan Clutch and repeat Step 5.

d. If the EGR cooler passes the off-engine leakcheck, if no other leaks are found and ifcooling system pressure is greater than theholding pressure noted in Step 1, and/or thedegas bottle cap continuously vents withloaded engine, perform PC/ED CoolingSystem Diagnostics for the Vistronic FanClutch. If Vistronic Fan Clutch passes orhas been replaced continue to Step 8. IfVistronic Fan Clutch fails replace theVistronic Fan Clutch and repeat Step 5.

e. If the EOT is within 25 degrees of the ECTFigure 5 - Article 08-11-3and the cooling system pressure is less

than the holding pressure noted is step 1NOTE

proceed to Step 9.THE CYLINDER HEAD MUST BE CLEANEDPRIOR TO CHECKING FOR FLATNESS OR YOUCAUTIONWILL GET IMPROPER READINGS.CAREFULLY RELEASE THE COOLING SYSTEM

PRESSURE WHILE REMOVING DEGAS CAP.CAUTIONIF THE INJECTORS ARE LEFT IN THE7. On Vehicle EGR Cooler Leak Test With EngineCYLINDER HEADS DURING THE REMOVAL ORWarm:INSTALLATION PROCESS INJECTOR DAMAGE

a. Install RADKITPLUSA on the degas tank. CAN OCCUR.

b. Regulate shop air to 100 psi (690 kPa) and d. Cylinder Head Handling Tips.apply vacuum to cooling system until gauge

• Avoid banging, dragging or scratching thestops decreasing or 20 inches of vacuum is

cylinder head at all times. When removingreached. (Degas bottle coolant level must

the cylinder head, lift the cylinder headbe set to “MIN” line with a cold engine to

straight up off of the dowels so as not toallow sufficient space for vacuum.)

nick the cylinder head.c. Hold vacuum and allow vacuum to stabilize. • Once the cylinder head is removed, place

the cylinder head on a bench with thed. If vacuum holds steady over 15 minutes gasket side up. If the gasket surface must

proceed to Step 6c-e. be turned down, use a piece of cleancardboard on the bench surface to protecte. If vacuum does not hold steady over 15the cylinder head from damage. Do notminutes proceed to Step 3 and 4 to test theallow the cylinder head to slide on theEGR Cooler off the vehicle and testing oilgasket surface, even on cardboard.cooler on vehicle.

e. Cleaning Cylinder Head Deck Surface.8. Head Gasket Replacement:

a. Refer to WSM, Section 303-01C for headremoval/installation and head flatnessspecification and replace the head gaskets.

PAGE 4

Page 5: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

TSB 08-11-3 (Continued)

The only tools approved by Ford Motor Company c. Change engine oil and oil filter.for cleaning the cylinder head and deck surface are

NOTEplastic (Figure 6) and wood scrapers, combined withON 2004 E-SERIES 6.0L BUILT BEFOREthe use of MotorcraftMetal Surface Prep. Ensure05/29/2004: IF THE OIL COOLER IS REPLACED,that the mating cylinder block deck surface isALSO REPLACE THE HEATER CORE INLETcompletely free of solid contamination, corrosion,HOSE; THE REVISED HOSE CONTAINS ANand fluids.INTERNAL FLOW RESTRICTOR (FIGURE 7).

NOTE REFER TO TSB 05-2-5 FOR ADDITIONALSTAINING OF THE METAL SURFACE IS INFORMATION.CONSIDERED NORMAL AND DOES NOT AFFECTSEALING ABILITY.

CAUTIONDO NOT CLEAN DECK SURFACES UNDER ANYCIRCUMSTANCE WITH STEEL RAZOR BLADES,ROTARY ABRASIVE DEVICES, OR ABRASIVESINCLUDING: ROLOC AND 3M BRANDEDSCOTCHBRITE PRODUCTS OR EQUIVALENTS,ROTARY WIRE BRUSHES, SINGLE HANDLEDWIRE BRUSHES, HAND ABRASIVES SUCH ASSANDPAPER OR EMERY CLOTH, ANY CARBONSTEEL BLADE. THESE PRODUCTS WILL CUTAND DAMAGE DECK SURFACES RESULTING INLEAKS. ABRASIVE PARTICLES MAY ALSO

Figure 7 - Article 08-11-3ENTER THE ENGINE CAVITIES CAUSINGINTERNAL ENGINE DAMAGE. USE OF THESE d. Remove the EBP sensor wire connector andTOOLS CAN ALSO GREATLY AFFECT THE inspect weather seal. If the seal is missing,FLATNESS OF THE SURFACE. replace the connector and EBP sensor.

e. Check for diagnostic trouble codes (DTCs).Perform the following inspection and tests.

(1) For 2004 (built after 9/29/03) - 2006F-Super Duty and 2004 (built after9/29/03) - 2005 Excursion: reprogramthe powertrain control module (PCM) tothe latest calibration using IDS releaseB39.12 and higher. This calibrationcontains a revised cooling fan strategyto help reduce the occurrence ofcoolant venting. Calibration files mayalso be obtained atwww.motorcraft.com.

Figure 6 - Article 08-11-3f. Perform Turbo Boost Test.

9. Vehicle Assembly:(1) If test FAILS refer to PC/ED Turbo

a. If the oil cooler, EGR cooler, or head Diagnostic Pinpoint Test KA for furthergaskets have been replaced, flush the details.cooling and heater system together using

(2) If test passes, repairs complete.Motorcraft Premium Cooling System Flush.

b. Use RADKITPLUSA 078-00592 to fill coolingsystem. Refer to WSM 303-03.

PAGE 5

Page 6: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

TSB 08-11-3 (Continued)

PART NUMBER PART NAMENOTEOVER-BOOST CONDITIONS (HIGHER THAN 3C3Z-9E933-BA Gasket Front EGR Cooler

3C3Z-9E933-AA Gasket Rear EGR CoolerSPECIFIED MGP) WILL RESULT IN EXCESSIVE3C3Z-6A831-AA O-Ring Oil Filter HousingCYLINDER PRESSURES, AND MAY BE CAUSED3C3Z-9A375-AA Washer Fuel BanjoBY ONE OF THE FOLLOWING: IRREGULAR3C3Z-9J469-AA O-Ring Heater Tube Front

RESPONSE IN VARIABLE GEOMETRY TURBO, 3C3Z-9229-AA O-Ring Kit InjectorBIASED EXHAUST PRESSURE SENSOR, AND/OR 3C3Z-6051-CA Head Gasket Kit Built Before 10/2003

(Figure 8 For Application)IRREGULAR EXHAUST GAS RECIRCULATION.6C3Z-6051-A Head Gasket Kit 20 mm Align Dowels

(Figure 8 For Application)PART NUMBER PART NAME4C3Z-6051-EA Head Gasket Kit 18 mm Align Dowels

3C3Z-9P456-AE EGR Cooler (Built Before 9/29/2003) (Figure 8 For Application)4C3Z-9P456-AF EGR Cooler (Built 9/29/2003 And 4C3Z-6051-DA Head Gasket Kit Over Size (Figure 8

After) For Application)3C3Z-6A642-AA Oil Cooler7C2Z-18472-A Hose - Inlet Heater Core (E-Series)6C3Z- 8A080-B Degas Bottle (F-Series)4C2Z-8A080-AA Degas Bottle (E-Series)4C2Z-18476-AA Heater Core (E-Series)4C3Z-18476-BA Heater Core (F-Series, Excursion)F6DZ-8100-A Cap - Degas BottleVC-1 Motorcraft Premium Cooling System

FlushZC-31-A MotorcraftMetal Surface Prep

(Continued)

Figure 8 - Article 08-11-3

PAGE 6

Page 7: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

TSB 08-11-3 (Continued)

OTHER APPLICABLE ARTICLES: 07-10-4, 05-2-5 081103A 2003 Super Duty, 2003 2.3 Hrs.WARRANTY STATUS: Eligible Under Provisions Of Excursion 6.0L: Includes

New Vehicle Limited Time To Install PressureWarranty Coverage Tester In-line with DegasIMPORTANT: Warranty Bottle and Pressurize thecoverage limits/policies are Cooling System Severalnot altered by a TSB. Times. Install RadkitplusWarranty coverage limits on the Degas Tank to Testare determined by the The EGR Cooler Onidentified causal part. Vehicle Twice, Replace the

OPERATION DESCRIPTION TIME Degas Cap if Required,081103A 2004-2008 Econoline 6.0L: 2.3 Hrs. Sand Degas Bottle Fill

Includes Time To Install Neck to Remove SmallPressure Tester In-line Nicks if Required. Installwith Degas Bottle and IDS/PVT, Road Test(s),Pressurize the Cooling Diagnosis of Fan Clutch,System Several Times. Check for DTC1s,Install Radkitplus on the Reprogram PCM to theDegas Tank to Test The latest Calibration andEGR Cooler On Vehicle Perform Turbo Boost TestTwice, Replace the Degas (Do Not Use With 6642A,Cap if Required, Sand 8080A, 8005D, 9456A,Degas Bottle Fill Neck to 8616A, 12342D1, 6051A,Remove Small Nicks if 6005F12, 6005F38) ThisRequired. Install IDS/PVT, Labor Operation May beRoad Test(s), Diagnosis of Claimed With OperationsFan Clutch, Check for B, C, D, E, F and G.DTC1s, Reprogram PCM to 081103A 2004-2007 Super Duty, 2.3 Hrs.the latest Calibration and 2004-2005 Excursion 6.0L:Perform Turbo Boost Test Includes Time To Install(Do Not Use With 6642A, Pressure Tester In-line8080A, 8005D, 9456A, with Degas Bottle and8616A, 12342D1, 6051A, Pressurize the Cooling6005F12, 6005F38) This System Several Times.Labor Operation May be Install Radkitplus on theClaimed With Operations Degas Tank to Test TheB, C, D, E, F and G. EGR Cooler On Vehicle

Twice, Replace the DegasCap if Required, SandDegas Bottle Fill Neck toRemove Small Nicks ifRequired. Install IDS/PVT,Road Test(s), Diagnosis ofFan Clutch, Check forDTC1s, Reprogram PCM tothe latest Calibration andPerform Turbo Boost Test(Do Not Use With 6642A,8080A, 8005D, 9456A,8616A, 12342D1, 6051A,6005F12, 6005F38) ThisLabor Operation May beClaimed With OperationsB, C, D, E, F and G.

PAGE 7

Page 8: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

TSB 08-11-3 (Continued)

081103B 2004-2007 Super Duty, 6.5 Hrs. 081103C 2004-2008 Econoline 6.0L: 0.4 Hr.2004-2005 Excursion 6.0L: Replace The Degas BottleIncludes Time To Remove if Required (Do Not Useand Leak Check EGR With 6642A, 8080A,Cooler off Engine, Test Oil 8005D, 9456A, 8616A,Cooler Using Radkitplus, 12342D1, 6051A,Replace EGR Cooler 6005F12, 6005F38). MayAnd/Or Oil Cooler if be Claimed WithRequired, Time to Flush Operations A, B, D, E, Fand Fill Cooling System, and G.Change Engine Oil and 081103C 2004-2007 Super Duty, 0.5 Hr.Filter. (Do Not Use With 2004-2005 Excursion 6.0L:6642A, 8080A, 8005D, Replace The Degas Bottle9456A, 8616A, 12342D1, if Required (Do Not Use6051A, 6005F12, 6005F38) With 6642A, 8080A,May be Claimed With 8005D, 9456A, 8616A,Operations A, C, D, E, F 12342D1, 6051A,and G. 6005F12, 6005F38). May

081103B 2003 Super Duty, 2003 5.9 Hrs. be Claimed WithExcursion 6.0L: Includes Operations A, B, D, E, FTime To Remove and and G.Leak Check EGR Cooler 081103C 2003 Super Duty, 2003 0.5 Hr.off Engine, Test Oil Cooler Excursion 6.0L: ReplaceUsing Radkitplus, Replace The Degas Bottle ifEGR Cooler And/Or Oil Required(Do Not Use WithCooler if Required, Time to 6642A, 8080A, 8005D,Flush and Fill Cooling 9456A, 8616A, 12342D1,System, Change Engine 6051A, 6005F12,Oil and Filter (Do Not Use 6005F38). May be ClaimedWith 6642A, 8080A, With Operations A, B, D,8005D, 9456A, 8616A, E, F and G.12342D1, 6051A, 081103D 2004-2007 Super Duty, 1.1 Hrs.6005F12, 6005F38) May 2004-2005 Excursion 6.0L:be Claimed With Replace Fan Clutch ifOperations A, C, D, E, F Required (Do Not Useand G. With 6642A, 8080A,

081103B 2004-2008 Econoline 6.0L: 8.2 Hrs. 8005D, 9456A, 8616A,Includes Time To Remove 12342D1, 6051A,and Leak Check EGR 6005F12, 6005F38). MayCooler off Engine, Test Oil be Claimed WithCooler Using Radkitplus, Operations A, B, C, E, FReplace EGR Cooler and G.And/Or Oil Cooler if 081103D 2004-2008 Econoline 6.0L: 1.7 Hrs.Required, Time to Flush Replace Fan Clutch ifand Fill Cooling System, Required (Do Not UseChange Engine Oil and With 6642A, 8080A,Filter (Do Not Use With 8005D, 9456A, 8616A,6642A, 8080A, 8005D, 12342D1, 6051A,9456A, 8616A, 12342D1, 6005F12, 6005F38). May6051A, 6005F12, 6005F38) be Claimed WithMay be Claimed With Operations A, B, C, E, FOperations A, C, D, E, F and G.and G

PAGE 8

Page 9: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

TSB 08-11-3 (Continued)

081103D 2003 Super Duty, 2003 1.1 Hrs. 081103F 2004-2008 Econoline 6.0L: 0.7 Hr.Excursion 6.0L: Replace Replace EBP Sensor AndFan Clutch if Required (Do Connector if Required (DoNot Use With 6642A, Not Use With 6642A,8080A, 8005D, 9456A, 8080A, 8005D, 9456A,8616A, 12342D1, 6051A, 8616A, 12342D1, 6051A,6005F12, 6005F38). May 6005F12, 6005F38) Maybe Claimed With be Claimed WithOperations A, B, C, E, F Operations A, B, C, D, Eand G. and G.

081103E 2003 Super Duty, 2003 13.6 081103F 2004-2007 Super Duty, 0.7 Hr.Excursion 6.0L: Replace Hrs. 2004-2005 Excursion 6.0L:Head Gaskets. Includes Replace EBP Sensor AndTime to Remove Clean Connector if Required (Doand Check Cylinder Heads Not Use With 6642A,for Flatness (Do Not Use 8080A, 8005D, 9456A,With 6642A, 8080A, 8616A, 12342D1, 6051A,8005D, 9456A, 8616A, 6005F12, 6005F38) May12342D1, 6051A, be Claimed With6005F12, 6005F38). May Operations A, B, C, D, Ebe Claimed With and G.Operations A, B, C, D, F 081103F 2003 Super Duty, 2003 0.7 Hr.and G Excursion 6.0L: Replace

081103E 2004-2007 Super Duty, 14.1 EBP Sensor And2004-2005 Excursion 6.0L: Hrs. Connector if Required (DoReplace Head Gaskets. Not Use With 6642A,Includes Time to Remove 8080A, 8005D, 9456A,Clean and Check Cylinder 8616A, 12342D1, 6051A,Heads for Flatness (Do 6005F12, 6005F38) MayNot Use With 6642A, be Claimed With8080A, 8005D, 9456A, Operations A, B, C, D, E8616A, 12342D1, 6051A, and G.6005F12, 6005F38). May 081103G 2003 Super Duty, 2003 1.4 Hrs.be Claimed With Excursion 6.0L: RemoveOperations A, B, C, D, F Glow Plugs to Vent Liquidand G. from Combustion

081103E 2004-2008 Econoline 6.0L: 19.8 Chambers Should Only BeReplace Head Gaskets. Hrs. Claimed If Engine IsIncludes Time to Remove Found To Be Hydro-lockedClean and Check Cylinder (Do Not Use With 6642A,Heads for Flatness (Do 8080A, 8005D, 9456A,Not Use With 6642A, 8616A, 12342D1, 6051A,8080A, 8005D, 9456A, 6005F12, 6005F38). May8616A, 12342D1, 6051A, be Claimed With6005F12, 6005F38). May Operations A, B, C, D, Ebe Claimed With and F.Operations A, B, C, D, Fand G

PAGE 9

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TSB 08-11-3 (Continued)

081103G 2004-2007 Super Duty, 1.4 Hrs. 081103H 2004 - Econoline 6.0L 0.5 Hr.2004-2005 Excursion 6.0L: Build Before 5-29-04:Remove Glow Plugs to Replace Heater Core InletVent Liquid from Hose (Do Not Use WithCombustion Chambers, 6642A, 8080A, 8005D,Should Only Be Claimed If 9456A, 8616A, 12342D1,Engine Is Found To Be 6051A, 6005F12,Hydro-locked (Do Not Use 6005F38)May be ClaimedWith 6642A, 8080A, With Operations A, B, C8005D, 9456A, 8616A, and D.12342D1, 6051A, DEALER CODING6005F12, 6005F38). May CONDITIONbe Claimed With BASIC PART NO. CODEOperations A, B, C, D, E 6051 42and F.

081103G 2004-2008 Econoline 6.0L: 2.2 Hrs.Remove Glow Plugs toVent Liquid fromCombustion ChambersShould Only Be Claimed IfEngine Is Found To BeHydrolocked (Do Not UseWith 6642A, 8080A,8005D, 9456A, 8616A,12342D1, 6051A,6005F12, 6005F38). Maybe Claimed WithOperations A, B, C, D, Eand F.

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Figure 9 - Article 08-11-3

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Page 12: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

Figure 10 - Article 08-11-3

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Page 13: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

Figure 11 - Article 08-11-3

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Page 14: COOLANT LOSS—6.0L TSB 08-11-3€¦ · 08/01/2009  · COOLANT LOSS—6.0L TSB 08-11-3 2003-2007 F-Super Duty FORD: 2004-2008 E-Series 2003-2005 Excursion This article supersedes

Figure 12 - Article 08-11-3

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