Modified Oil Cooler vs Original for Mk6 2.4 DI

[fancourt]

Hi everyone,

First post here - usually I can find my question answered previously elsewhere but haven't been able to definitively get to the bottom of this one. Apologies if my forum searching skills are lacking!

Van is a 2003 Mk6 2.4 DI RWD Luton with the D2FB engine.

The oil cooler has failed (externally leaking coolant from oil cooler radiator as well as oil from somewhere nearby) and I'm looking for a replacement. TPUK and others on ebay are selling a modified oil cooler with metal screw-on oil filter instead of the original paper filter with plastic cap type.

I've seen one thread where there was a warning about modified oil coolers having the coolant hoses attaching in different locations with one being a different diameter and this causing headaches to fit, but it wasn't 100% clear.

Question 1): Am I correct in assuming because there is a coolant leak from the oil cooler radiator and an oil leak from either a failed gasket, hairline crack in the plastic filter cap or something else I'm better off buying a whole new assembly instead of replacing just the oil cooler radiator and gaskets?

Question 2): Is the "modified oil cooler" a ford updated part design that supersedes the type originally fitted or is this an aftermarket modification not approved by ford?

Question 3): Are there any benefits to the modified design other than not having the weak plastic filter cap and are there any reasons to seek out the original part for replacement instead of the modified part?

Any other advice or info about replacing the oil cooler would be gratefully received!

Many thanks,
Rob.

[Jim Archer]

I fitted one to my 02 Jumbo. You need the correct length bolts for the modded mounting flange, and the hoses fitted fine.

It is a fecker to get to some of the bolts though.

Jim

[knobby1]

I fitted one to my 02 Jumbo. You need the correct length bolts for the modded mounting flange, and the hoses fitted fine.

It is a fecker to get to some of the bolts though. Jim

+1..^^

Lord Knobrot

[fancourt]

Thanks guys,

Are there any pluses/minuses for the modified part versus the original design, other than removing the weakness of the plastic filter cap? Did I read something about a thermostat being moved/removed from the cooler?

I don't suppose you happen to remember what size the bolts I'll need to source are?

Cheers,
Rob.

[paul2012]

It's a Ford revised part.

Also available for mk7 2.2 engines.

IMG_1387.JPG

[fancourt]

Thanks Paul - I suspected it was a Ford revised design, but wasn't certain.

Are the bolts required to mount it just slightly longer than the original ones?

Also, do you know the part number for the screw-on metal can type oil filter since I won't be able to use my registration to find the correct part from suppliers anymore?

Cheers,
Rob.

[fancourt]

Ok, here's an update on the situation...

I ordered the modified oil cooler off ebay, it was poorly packaged and one of the coolant pipe fitting lips has been dented. Unfortunately I didn't notice this until after I'd received the package... It is made from quite dodgy looking cast metal with no makers marks or part numbers at all stamped anywhere on it. The oil pressure sensor thread is drilled off-centre from its casting and the threaded hollow stud for the oil filter mount is loose with no lip for it to tighten against internally.

Anyway, it appears that all six bolts need to be different lengths than for the original part. In the original part the bolt threads all appear to engage about 15mm into the engine block. It looks possible to reuse one of the original two long (70mm) bolts, but it will only be engaged about 10-11mm instead of 15mm into the block. Ideally the "revised" cooler housing appears to require five short bolts (10mm hex head M8 x 35mm long) and one long bolt (10mm hex head M8 x 75mm long). The original part had two 70mm long and four 25mm long M8 bolts.

The coolant hose connections are different diameters - I can only assume the outlet one is the larger of the two (logically it wouldn't make sense to have the outlet narrower than the inlet) and it looks highly unlikely that the hose for the connection that has been moved from the top of the cooler radiator (original part) to the oil filter mount casting (modified part) will be long enough to reach.

The overall appearance of the modified part leaves me rather dubious as to its quality and potential reliability.

I rang a genuine Ford parts dealer to enquire about the genuine part available from Ford and whether this "revised" design was initiated by Ford. The bloke I spoke to was very clear that the genuine part (£560 + VAT!!!) had NOT been revised and still had the plastic oil filter cap. He claimed that ONLY the Mk7 has a screw-on metal can oil filter.

All this leaves me wondering whether I shouldn't just return the low-quality ebay modified part and just replace the failed gaskets/radiator...

Any thoughts from experts on here?

Cheers,
Rob.

[Retired John]

I got mine from Mick at http://fordtransitparts.com.au/ it came with all the correct bolts etc and was a genuine Ford article the only problem was the existing water hoses were not long enough

[Jim Archer]

My mk6 was a 125, and other than the bolts being different, it was a straight-ish swap hoses wise - recall I had to shorten the one that went to the 'stat by about 1/2"(?).

It's now on my 60 plate Mk7, and as it was designed for the later set-up, all the hoses fitted as they should.

Mine came from TPUK and was better quality than the £65 price would suggest.

You have got the correct fitment?

Jim

[fancourt]

Hi Jim,

Yeah I confirmed correct fitment over the phone before purchase. I didn't go with TPUK this time because another competitor offered slightly faster delivery... Regretting my haste as it has slowed down the whole repair!

TPUK are now charging £45.90 which is within 5p of the price I paid. Did your TPUK one have any identifying marks from the manufacturer? I got a vacuum pump from them and its quality looked great and hasn't let me down! It did have a serial number and manufacturer stamp too.

Cheers,
Rob.

[paul2012]

Ok, here's an update on the situation...

I ordered the modified oil cooler off ebay, it was poorly packaged and one of the coolant pipe fitting lips has been dented. Unfortunately I didn't notice this until after I'd received the package... It is made from quite dodgy looking cast metal with no makers marks or part numbers at all stamped anywhere on it. The oil pressure sensor thread is drilled off-centre from its casting and the threaded hollow stud for the oil filter mount is loose with no lip for it to tighten against internally.

Anyway, it appears that all six bolts need to be different lengths than for the original part. In the original part the bolt threads all appear to engage about 15mm into the engine block. It looks possible to reuse one of the original two long (70mm) bolts, but it will only be engaged about 10-11mm instead of 15mm into the block. Ideally the "revised" cooler housing appears to require five short bolts (10mm hex head M8 x 35mm long) and one long bolt (10mm hex head M8 x 75mm long). The original part had two 70mm long and four 25mm long M8 bolts.

The coolant hose connections are different diameters - I can only assume the outlet one is the larger of the two (logically it wouldn't make sense to have the outlet narrower than the inlet) and it looks highly unlikely that the hose for the connection that has been moved from the top of the cooler radiator (original part) to the oil filter mount casting (modified part) will be long enough to reach.

The overall appearance of the modified part leaves me rather dubious as to its quality and potential reliability.

I rang a genuine Ford parts dealer to enquire about the genuine part available from Ford and whether this "revised" design was initiated by Ford. The bloke I spoke to was very clear that the genuine part (£560 + VAT!!!) had NOT been revised and still had the plastic oil filter cap. He claimed that ONLY the Mk7 has a screw-on metal can oil filter.

All this leaves me wondering whether I shouldn't just return the low-quality ebay modified part and just replace the failed gaskets/radiator...

Any thoughts from experts on here?

Cheers,
Rob.

Yes it's a revised part for the mk7 2.2 & 2.4 engines.

I got mine from TPUK. (Transit Parts UK) - They are a member on this this forum

Genuine OEM part with Ford part no on it.

IMG_1387.JPG

Fitted to mk7 2.2 engine. Didn't have to change bolts.

IMG_1623.JPG

available here

https://www.ebay.co.uk/itm/FORD-TRANSIT ... SwGvhT9NT6
https://www.ebay.co.uk/itm/FORD-TRANSIT ... SwICpZ53M0

[fancourt]

I had another look at TPUK's listings and noticed that they also sell a replacement radiator for the original design which is MORE expensive than the whole new "modified" cooler, filter and filter mount they also sell, however it appears to have proper cooling fins on it, like the original...

https://www.ebay.co.uk/itm/TRANSIT-OIL- ... 1641289724?

Vs:

https://www.ebay.co.uk/itm/FORD-TRANSIT ... 2870925789?

TPUK if you're here, any chance you could clarify?

Cheers,
Rob.

PS: scrutinising the photos of the TPUK part more closely seems to indicate several ways in which it looks better designed than the one I'm regretting having bought!

[Jim Archer]

Been a while since I've had to look at mine, but pretty sure it had 'Ford' markings on it, and whilst it was in a plain box, had Ford P/No on the label.

Jim

[fancourt]

Thanks Jim - I wonder if TPUK have switched suppliers? Before I placed my order with the other seller, I rang TPUK to clarify delivery time and whether the part was genuine or aftermarket and they confirmed it was NOT a Ford genuine part...

Rob.

[fancourt]

Right, the plot thickens!

Just rang TPUK again and got a very helpful chap who I wish I'd gotten to speak to in the first place!

He said they aren't officially a Ford parts dealer so aren't allowed to sell Ford "genuine" parts, but the oil coolers they sell are original equipment taken off original Ford engines.

I'm going to send back the dodgy one and buy one from TPUK... wish me luck!

Rob.