From what I have seen before, people have had to flush the coolant system VERY well to get the oil out. If you want to do it yourself, thats no problem just follow the GOOCH procedure. But it is a long process to do by yourself, and uses a lot of distilled water.
I have done it before, but last time I just said screw it and took it to Ford. They did a power flush (which the Gooch method is not) and used a chemical cleaning agent to clean instead of just water. Of course you can also buy the chemical from Ford if you wanted. In the end the $160 I gave to Ford was worth it to me.
Flush it with tap water and dishwasher soap. The DW soap is good at cutting and holding the oil in suspension. You may have to do it several times. Once you get clean water draining, then finish up with the distilled water and correct amount of anti-freeze mix.
You say you are adding oil but how much oil are we talking that you have added since you did all the work? Are we talking a quart of oil or are we talking a gallon or more? It is possible that you have a cracked injector cup but without more details it is hard if not impossible to diagnose over a computer screen.
I had to change an injector cup in my 7.3 power stroke but that was due to diesel fuel getting in my coolant ! I do remember a long time ago having chocolate milk frothy coolant that was due to oil getting in the coolant but I cant remember if that was from my internal transmission lines leaking into the radiator or something to do with the Engine oil cooler.
gtx,
I had a bad oil cooler and the oil in my coolant tank was pretty thick. Before I did the oil cooler repair, I didn't notice any loss of oil or the need to add oil to keep the correct level. Maybe you have other issues like the cracked injector cup mentioned.
On the flush issue. I flushed my truck I think over 10 times with simple green and then liquid dish washing detergent before I changed the oil cooler. Then I did the full GOOCH procedure after changing the oil cooler.
Also I changed the radiator, all coolant/heater hoses, degas bottle, t-stat, water pump, etc. No sign of oil in the coolant system afterwards.
Even if you damaged an o-ring on the oil cooler R&R I don't think you would be loosing that much oil to the coolant system. Good Luck.
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