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I've been doing quite a few oil cooler reseals lately due to the cold weather and decided since I've ran across a few threads on them, I decided to do a write up on how to. I did this one this morning in about 45 minutes. E99 F-450 2wd.

First, drain the coolant from the driver's side of the block by removing the block heater element.



Here's the removed oil cooler all covered with nasty, baked-on grease.
3 bolts above the oil filter and 2 bolts into the front cover.



Next, I use a rubber dead blow mallet to remove the end caps. They usually fall right off since the seals are hard and brittle.



Here is the oil cooler after cleaning. I usually don't try to clean out the core passages since the oil side is full of fins that can collect dirt and grease....then end up in the engine lubrication system. Just clean the exterior of the core to reduce the chance of damage. The center of the core contains the coolant passages.




I use trans-gel or vasoline to lubricate the o-rings for reassembly. Here is some white grease to show in detail where I lubricate. Don't forget to lubricate the inner chamfer for the coolant o-ring.




Here is how I press the end caps back on the core. The core will eventually slide into the end caps. No laughing at my bald spot or gray hairs.
Also note the locating tab on the rear end cap.





Good luck with the installation of your completed oil cooler reseal. Don't forget to remove the old gaskets and clean the block mating surfaces before torquing the attachment bolts to 18 ft.lbs.
 
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