Low Power/Low Boost Performance - 2004-2005 Ford With 6.0L Diesel Engine

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LOW POWER – COLD SIDE CHARGE AIR COOLER (CAC) DISCONNECTED – OIL LEAK AT CAC CONNECTIONS – 6.0L ENGINE – VEHICLES BUILT 4/1/2004 THROUGH 2/20/2005

FORD

2004-2005 Excursion, F-Super Duty

2004-2005 F-Super Duty and Excursion vehicles built 4/1/2004 through 2/20/2005 equipped with a 6.0L diesel engine may exhibit an oil leak from the cold side charge air cooler (CAC) duct connections, or low power/low boost performance due to the plastic charge air cooler duct becoming disconnected (blowing off).

ACTION:

Determine the specific issue with the CAC duct on the vehicle that is being serviced, and perform one (1) of the following:

If the CAC duct has separated from the engine intake manifold, or leaks oil excessively at the engine intake manifold elbow connection, install a reinforcing ring. Refer to the Reinforcing Ring Installation Service Procedure.
If the CAC duct has separated from the CAC, leaks oil excessively at the CAC connection, or has a hole or other defect in the duct, replace the duct with a CAC Metal Duct Kit. Refer to the Metal Duct Kit Installation Service Procedure.

SERVICE PROCEDURE

NOTE: OIL FOUND IN 6.0L CAC SYSTEM MAY BE GREATER THAN AMOUNTS PREVIOUSLY FOUND IN THE 7.3L ENGINE, DUE TO HIGHER BOOST LEVELS. A RESTRICTED AIR FILTER CAN ALSO CONTRIBUTE TO GREATER AMOUNTS OF OIL IN THE CAC SYSTEM. ENGINE OPERATION WITH A RESTRICTED AIR FILTER INCREASES THE AIR FLOW THROUGH THE OIL SEPARATOR, LEADING TO GREATLY INCREASED OIL IN THE BLOW-BY GAS AND RESULTING IN OIL PUDDLING IN THE DUCTS. PROPER AIR FILTER MAINTENANCE IS IMPORTANT. DUSTINESS AROUND THE CAC DUCT CONNECTIONS IS CONSIDERED NORMAL.

NOTE: IF A CAC DUCT CLAMP IS BROKEN, A SERVICE CLAMP IS AVAILABLE (1C3Z-6K786-BA). IT IS NOT NECESSARY TO ORDER A DUCT KIT TO OBTAIN A CLAMP.

REINFORCING RING INSTALLATION

Clean the connecting port and the inside surface of the duct that is being serviced with Motorcraft Metal Brake Parts Cleaner (PM-4).
Place the reinforcing ring in the groove under the clamp at the engine end of the duct. Place the gap in the ring on the side of the duct opposite from where the bolt on the clamp will be located (Figure 1).

Figure 1

After installing the engine end of the duct, position the internal bead of the duct into the groove in the engine elbow and hand torque the clamp to 106 lb-in (12 N-m).

CAUTION: DO NOT OVER-TORQUE THE CLAMP.

Verify the torque on the CAC end of the duct is 106 lb-in (12 N-m).

METAL DUCT KIT INSTALLATION

Remove residue from both connecting ports and the inside surface on both ends of the duct with Motorcraft Metal Brake Parts Cleaner (PM-4).
Install CAC Metal Duct Kit.
After installing new duct on both ports, position the internal bead of the duct into the groove in the engine elbow. Hand torque the clamp to 106 lb-in (12 N-m).
Push the other end squarely and fully onto the CAC port. Hand torque the clamp to 106 lb-in (12 N-m).

NOTE: MAKE SURE THAT THE CLAMP BOLT IS POSITIONED SO THAT IT WILL NOT BE STRUCK BY THE HOOD WHEN CLOSED.

Ford 6C3Z-6C640-AA - CONNECTION - AIR INL

PART NUMBER	PART NAME
5C3Z-6F082-AA	Reinforcing Ring
6C3Z-6C640-AA Ford 6C3Z-6C640-AA - CONNECTION - AIR INL Genuine Ford Part 6C3Z-6C640-AA Engineered by Ford specifically for your vehicle Ford quality construction Warrantied by Ford Motor Company Customer will be contacted if core charge applies to part. $257.58 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-19 / Affiliate links / Images from Amazon Product Advertising API	Metal Duct Kit
1C3Z-6K786-BA 16 Reviews Dorman 904-220 Intercooler Boot Kit Compatible with Select Ford Models Direct replacement - this intercooler boot kit is designed to match the original seals required to reseal and repair intercooler boot on specified vehicles Ideal solution - this kit is a reliable replacement for original components that are leaking or have failed Durable construction - this kit is made from quality components to ensure reliable performance and a long service life Trustworthy quality - backed by team of product experts in the United States and more than a century of automotive experience Ensure fit - to make sure this part fits your exact vehicle, input your make, model and trim level into the garage tool $122.18 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Clamp
PM-4	Motorcraft Metal Brake Parts Cleaner

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