ACTION The hot-side CAC duct is no longer available as an assembly. Should CAC repairs become necessary, individual components must be ordered to rebuild the duct assembly. Refer to the Service Tips. SERVICE TIPS Carefully inspect all components for holes, tears, cuts, abrasion, oil saturation or sponginess, and order only the components needing replacement. Use new clamps rather than reusing the old. Thoroughly clean all components, both new and reused, especially in the joint clamp areas, as well as the turbo and CAC connections, using PM-4 Motorcraft Brake Cleaner. If the curved turbo hose must be replaced, mark the metal duct adjacent to the faint white alignment mark on the old hose (top position in vehicle) before removing it from the duct. Then install the new hose so its alignment mark is adjacent to the mark made on the metal duct. Position and torque clamps. Carefully reinstall the rebuilt duct assembly. Torque all four (4) clamps to 9 lb-ft (12 N.m) only; over tightening will damage the component. Check all joints for leaks using soapy water. NOTE:BEFORE REBUILDING AND INSTALLING THE DUCT, OBSERVE THE COLOR OF THE INSIDE SURFACE OF EACH HOSE. If Blue (B) Apply a thin uniform coating of TA-31 Motorcraft RTV Silicone Sealant to the sealing surfaces of the hose and to the mating duct and fitting. After reassembly and reinstallation, allow to cure for three (3) hours before starting the engine. These steps will help prevent joint separation. If Red-Orange (R-O) Do not apply any sealant/adhesive, as this hose has inherent adhesive properties.

Part Number Part Name 6C2Z-6K786-AA Clamp 6C3Z-6K786-CA Clamp 6C3Z-6C640-C Turbo Hose – Shorter Hose (B) or (R-O) – Before 10-14-2004 6C3Z-6C640-A Turbo Hose – Longer Hose (R-O) – From 10-14-2004 6C3Z-6C640-B CAC Hose (R-O) 5C3Z-6K769-BA Metal Duct-Dual Generator – Shorter Duct – From 10-14-2004 6C3Z-6K769-A Metal Duct-Dual Generator – Longer Duct – Before 10-14-2004 5C3Z-6K769-AA Metal Duct-Single Generator – Shorter Duct – From 10-14-2004 6C3Z-6K769-B Metal Duct-Single Generator – Longer Duct – Before 10-14-2004 PM-4-B Motorcraft Metal Brake Parts Cleaner TA-31 Motorcraft RTV Silicone Sealant

Ford 6.0 Powerstroke Intercooler Leak | Oil Seepage

Q: Description

Reference Number(s): 07-5-15, Date of Issue: March 19, 2007 FORD: 2003-2005 Excursion; 2003-2007 F-Super Duty Superceded Bulletin(s): 07-3-1, Date of Issue: February 19, 2007 NOTE: This article supersedes TSB 07-3-1 to update the Service Parts. ISSUE Some 2003-2005 Excursion and 2003-2007 F-Super Duty vehicles, equipped with the 6.0L diesel engine, may exhibit oil seepage or a boost pressure leak at the hot-side charge air cooler (CAC) duct assembly connections.

Q: Warranty Information

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage. IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. DEALER CODING Basic Part No. Condition Code 6C646 42

Description

Reference Number(s): 07-5-15, Date of Issue: March 19, 2007

FORD: 2003-2005 Excursion; 2003-2007 F-Super Duty

Superceded Bulletin(s): 07-3-1, Date of Issue: February 19, 2007

NOTE: This article supersedes TSB 07-3-1 to update the Service Parts.

ISSUE

Some 2003-2005 Excursion and 2003-2007 F-Super Duty vehicles, equipped with the 6.0L diesel engine, may exhibit oil seepage or a boost pressure leak at the hot-side charge air cooler (CAC) duct assembly connections.

ACTION

The hot-side CAC duct is no longer available as an assembly. Should CAC repairs become necessary, individual components must be ordered to rebuild the duct assembly. Refer to the Service Tips.

SERVICE TIPS

Carefully inspect all components for holes, tears, cuts, abrasion, oil saturation or sponginess, and order only the components needing replacement. Use new clamps rather than reusing the old.
Thoroughly clean all components, both new and reused, especially in the joint clamp areas, as well as the turbo and CAC connections, using PM-4 Motorcraft Brake Cleaner.
If the curved turbo hose must be replaced, mark the metal duct adjacent to the faint white alignment mark on the old hose (top position in vehicle) before removing it from the duct. Then install the new hose so its alignment mark is adjacent to the mark made on the metal duct. Position and torque clamps.
Carefully reinstall the rebuilt duct assembly. Torque all four (4) clamps to 9 lb-ft (12 N.m) only; over tightening will damage the component. Check all joints for leaks using soapy water.

NOTE:BEFORE REBUILDING AND INSTALLING THE DUCT, OBSERVE THE COLOR OF THE INSIDE SURFACE OF EACH HOSE.

If Blue (B)

Apply a thin uniform coating of TA-31 Motorcraft RTV Silicone Sealant to the sealing surfaces of the hose and to the mating duct and fitting.
After reassembly and reinstallation, allow to cure for three (3) hours before starting the engine. These steps will help prevent joint separation.

If Red-Orange (R-O)

Do not apply any sealant/adhesive, as this hose has inherent adhesive properties.

Part Number	Part Name
6C2Z-6K786-AA	Clamp
6C3Z-6K786-CA	Clamp
6C3Z-6C640-C	Turbo Hose – Shorter Hose (B) or (R-O) – Before 10-14-2004
6C3Z-6C640-A	Turbo Hose – Longer Hose (R-O) – From 10-14-2004
6C3Z-6C640-B	CAC Hose (R-O)
5C3Z-6K769-BA	Metal Duct-Dual Generator – Shorter Duct – From 10-14-2004
6C3Z-6K769-A	Metal Duct-Dual Generator – Longer Duct – Before 10-14-2004
5C3Z-6K769-AA	Metal Duct-Single Generator – Shorter Duct – From 10-14-2004
6C3Z-6K769-B	Metal Duct-Single Generator – Longer Duct – Before 10-14-2004
PM-4-B	Motorcraft Metal Brake Parts Cleaner
TA-31	Motorcraft RTV Silicone Sealant

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.

IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

DEALER CODING

Basic Part No.	Condition Code
6C646	42

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