Oil Cooler: Disassembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the oil cooler. For additional information, refer to OIL COOLER . If the oil cooler is being removed as part of an engine disassembly, refer to DISASSEMBLY .

NOTE: Do not discard the oil cooler cover bolts. They are self-tapping bolts and will be used for assembly.

Fig 1: Locating Bolts And Oil Filter Base

Courtesy of FORD MOTOR CO.

Remove the 8 bolts and the oil filter base.
- Remove and discard the gaskets.
Remove the 2 bolts and the EGR cooler supply cover.
- Remove and discard the press-in-place gasket.
- Drain any remaining oil from the oil cooler assembly.
Fig 2: Locating Bolts And EGR Cooler Supply Cover
Courtesy of FORD MOTOR CO.
Remove the EGR coolant supply port.

Fig 3: Locating EGR Coolant Supply Port
Courtesy of FORD MOTOR CO.

NOTE: Do not discard the nuts from the oil cooler cover, they will be reused.

Fig 4: Locating Oil Cooler-To-Oil Cooler Cover Nuts

Courtesy of FORD MOTOR CO.

Remove the 2 oil cooler-to-oil cooler cover nuts.

NOTE: Do not discard the bolts from the oil cooler cover, they will be reused.

Fig 5: Locating Oil Cooler-To-Oil Cooler Cover Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 oil cooler-to-oil cooler cover bolts.
Using 2 pieces of wood, position the oil cooler assembly so that the oil cooler is suspended between the wood.

Fig 6: Identifying Pieces Of Wood
Courtesy of FORD MOTOR CO.

NOTE: The oil cooler cover may be difficult to remove. Use care so that the oil cooler cover is not damaged and can be reused.

Fig 7: Locating Oil Cooler And O-Ring Seals

Courtesy of FORD MOTOR CO.

Using the Front Axle Shaft Bearing Installer and Handle over the inlet and outlet port and tap with a hammer.
- Alternate between the inlet and outlet port until the oil cooler is removed from the cover.
- Discard the oil cooler and O-ring seals.
Remove and discard the blue oil cooler cover gasket from the oil cooler cover.

Fig 8: Locating Blue Oil Cooler Cover Gasket
Courtesy of FORD MOTOR CO.
Remove and discard the 3 O-rings from the oil cooler cover.

Fig 9: Locating O-Rings
Courtesy of FORD MOTOR CO.

NOTE: Not all oil cooler covers will have a threaded insert, some will have a cast boss. If the oil cooler cover has a threaded insert, the O-ring needs to be removed.

NOTE: Do not discard the threaded insert.

Fig 10: Locating Oil Cooler Cover

Courtesy of FORD MOTOR CO.

If equipped with a threaded insert, remove the threaded insert from the oil cooler cover by pushing down on the insert from the top of the oil cooler cover.
If equipped with a threaded insert, remove and discard the O-ring seal from the threaded insert.

Fig 11: Locating O-Ring Seal
Courtesy of FORD MOTOR CO.
Inspect the oil cooler cover for damage at the oil filter base and EGR cooler coolant supply cover.

Fig 12: Locating Oil Filter Base And EGR Cooler Coolant Supply Cover
Courtesy of FORD MOTOR CO.
Inspect the oil cooler cover for the following:
- sealing surfaces and threads for damage.
- O-ring seal bores of the oil cooler cover were not damaged during the oil cooler removal.
- Clean the oil cooler cover and remove any scale deposits with a wire brush.
Using compressed air make sure the drain hole on top of the oil cooler cover is clear of any debris.

Fig 13: Locating Drain Hole On Top Of Oil Cooler Cover
Courtesy of FORD MOTOR CO.
NOTE: The vent hole is located on the left side, next to the passage, underneath the oil cooler cover.

Using compressed air make sure the vent hole underneath the oil cooler cover is clear of any debris.

Fig 14: Locating Vent Hole
Courtesy of FORD MOTOR CO.