Engine Oil Cooler Replacement - 2002 Ford F-250 7.3L Powerstroke

Watch for helpful tips on replacing the Engine Oil Cooler on your F-250 with a 7.3L Powerstroke engine
Level of difficulty: Expert
Approximate time: 5 Hours
Tools needed: 3/8" 10mm, 12mm and 18mm socket. 3/8" Ratchet. 3/8" 3" and 6" extension. Prybar.
Additional tools: Phillips head and flat head screwdriver. Oil filter wrench. Pliers. Drain pans for oil and coolant.
Installation Notes: Make sure the old gaskets come off prior to installing the new cooler and mounting gaskets.
Vehicle used: 2002 FORD F-250 7.3L POWERSTROKE
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Motorist: If this job is beyond your skill level, visit your automotive service professional.This video is for general information purposes only. The provider makes no representations or warranties as to the information contained in this video or its usage, completeness, quality or accuracy. Any use of such information is at the user's sole risk, and in no event shall the provider be liable for any consequential, incidental, special, punitive or direct or indirect damages arising from such use.

[@DJC991]

I did my 2002 F350 oil cooler seal job today. Wasn't too bad but is a mess especially since mine has been leaking a long time.I used OEM seals and gaskets. Drained coolant and removed oil filter prior to removing the cooler. I did not remove the lower radiator hose as I was able to get on both front bolts laying underneath from the front. It is tight but wasn't much of a problem. I took the unit out as a single piece. After taking apart the ends from the tube, I cleaned everything up, lightly sanded where the seals go and the gasket mating surfaces and used a long clamp to squeeze the ends back on the tube with both ends and the seals well lubed. I got all the bolts in and snugged, then tightened to 18 ft lbs per the info I looked up. Drained oil and while it was draining I refilled the coolant with new coolant (5 plus gallons). Ran it down the road and back a few miles, don't see anything dripping but I'll know better in a couple days after running it a bit. Messy job but all in all not that bad. Takes as long to disassemble, clean and reassemble as it does to get it out and back in. Then of course a little time for coolant and oil change. Give yourself a few hours and you should have it done.

[@rodneynamanda3786]

Warning. It might seem easier to slide the cooler together with the front end cap bolted to the engine but you can brake the cast aluminum front cover like I did and then have to pull the engine. Put it together in the press and then install it.

[@htatesil4192]

U still around

[@therealjeeposaurus]

Good video. This will help me when I tackle this job

[@tonyroulette6179]

Make sure you lubricate the O rings on both ends before re assembly,so they slide into their housings easier

[@danielhay2217]

We graeased the whole thing and it still wont go together enven with 1000 pounds of pressure

[@optimalorlando]

Thank you your steps saved me valuable time on the install

[@akquicksilver]

Good video, unfortunately my F250 is a 4X4, what a pain to get to with the front pumpkin and drive shaft!

[@Ffmt-ri3ti]

Difficulty level: Expert Shooot son guess I’m an expert mechanic

[@yh9206]

Very imformative detailed video. Ty

[@tonyslagle6772]

Why doesn't anybody cover that spring-loaded plunger located on the filter housing side? What order do the parts go in when replacing?

[@felixstanis7832]

Exactly! Good question!

[@nickxwc9508]

im about too mine aswell as a water pump. but 5 hrs seems alittle much.

[@MrJayprojects]

I had plastic pieces in the front of the oil cooler blocking some of the coolant copper tubing.

[@mariogrande5783]

Let us know what size is the bolts or tools that we needed

[@optimalorlando]

10mm socket for the 5 bolts.

[@truebengalsfan]

What brand gasket did you use

[@donscott2500]

Would you mind letting me know where you got the replacement cooler and the gasket kit ? I have a 2006 F-250 and I am hoping the oil cooler removal is the same on mine as your video.

[@ShamikaServer]

This is on a 7.3L (1999-2003) a 2006 would have a 6.0 and is completely different setup and and a lot more involved.

[@jarrodbaker575]

Don Scott Lol yeah not quite bud. I’ve done both, 6 liter is a lot more involved. A lot.

[@tylerwerner6413]

@@ShamikaServer This is a 7.3, the 6.0 is up top in the center of the engine. VERY involved process and while you may be able to do it with the cab on (EXTREMELY UNLIKELY) you will litterally save 6-8 hours by just lifting the cab off the frame.

[@mattsprayberry0]

A whole lot of patience with a old 7.3

[@JohnHynes_at_lookituplive]

Did anyone have to raise engine or remove power steering pump?

[@wansolve2036]

I may have missed this in the video, but what was the initial reason/symptom for replacing the cooler seals/gasket ? Was it leaking ? There didn't appear to be oil leaking around it from the video. Thanks for putting this up, very helpful.

[@4BigGreen]

It may have been preventative maintenance. If you wait too long and the o-rings leak, you have oil in your coolant system. Then you have a big time cleanup procedure to deal with if you want to correct it properly. I think if I remember the O-rings last between 100-140k miles.

[@thiagomasci1604]

4BigGreen Exactly! I bough a 99 7.3 and have oil in coolant system. That’s the first think to do, replace oil cooler and gaskets, clean up a whole coolant system and cross the fingers.

[@johnmclaren7059]

Awesome job! I did mine about 10 years ago and now after a severe cold snap which I had no way of plugging the ol girl in on start up after work she was leaking pretty good , I just hung my head and knew the job ahead of me was going to be just as messy as the first time but after watching how you assembled that cooler it’ll go easier ! Thank you 👍

[@NickySull]

I guess I’m an expert level mechanic 😬

[@xoutlawmarinex]

7.3 diesel oil cooler replacement

[@bill_mosienko]

What are the torque settings on the bolts?

[@thewanderer899]

Bill Mosienko Tights good, too tight is broken But really, google it.