Td5 oil cooler catastrophic failure

[Hendrik]

Hi all
Walked into the garage yesterday to find oil absolutley everywhere. Had a look and the oil that leaked out had coolant in it as well :o This might explain why I have been having oil in the expansion tank. I thought it was just a little oil that leaked into the coolant galleries in the block when the head was removed and didn't really think much of it.

I looked at the main filter, no leaks, then saw that the leak came from the oil cooler where it mates to the block. Now I have not stripped it yet, but is it common for the gasket to fail...or the whole cooler itself???

Any thoughts would be much appreciated.

[justinc]

Hi Hendrick, There is a gasket and a couple of Orings, and yes it is possible that your cooler has failed, I've seen a few fail at low km from electrolysis etc. I'd be removing and inspecting, pressure test the unit and see where to go from there. BTW, the last one I tested it was immersed in fluid and pressurised to 100psi but no signs of a leak. When hot however, it leaked alright:mad: Don't take any chances, any pitting or corrrosion visible just chuck it. The results of it failing while running can be very expensive, burst radiator, heater core, all the hoses ruined etc etc:(

JC

[Hendrik]

Thanks for that JC, just such an unexpected thing to happen. So does the pitting etc occur in the matrix inside or inside the casing itself? How does the oil cooler work, I had a look at rave, but can't really get a good idea how it works.

[justinc]

Thanks for that JC, just such an unexpected thing to happen. So does the pitting etc occur in the matrix inside or inside the casing itself? How does the oil cooler work, I had a look at rave, but can't really get a good idea how it works.

Funnily (Well, not really:mad:) the pitting was worse on the stainless steel actual element part:o where the oil escaped into the cooling system (at 70+ psi:o) The stainless oil element is connected to the alloy housing and sealed with fittings and O rings (These are the common culprit as they can become hard etc) and coolant is circulated around the element. The whole housing is bolted to the block and has the oil pressure light sender unit and the connection to the centrifugal filter housing.

As I said, if in any doubt toss it out. Rovacraft etc should have them for good $$$. They aren't cheap but cheaper than some other manufacturers oil coolers:eek:

JC

[George130]

The coolers do fail.
I was quoted $1100 3 years ago to buy a new one as you can't just uy the cooler but have to uy the whole assemly unless things have changed.

[justinc]

The coolers do fail.
I was quoted $1100 3 years ago to buy a new one as you can't just uy the cooler but have to uy the whole assemly unless things have changed.

Yes that is still the case Ed, but now can be had for around $950 odd last time I looked. Not sure if anyone is making aftermarket ones yet, but I'd not take the chance:(

JC

[Hendrik]

Had a look at some gen ones from LR series, they are around $500, with freight its probably $650-700 landed...which is alright. I am hoping mine is fine, I have spent sooooo much money on this car lately starting to think if its worth keeping it. I am so hoping that this will be end of my issues with this car, as everything has been replaced. Only things left to fail are the water pump, fuel pump and the radiator to catastrophically fail.

[Grumpy]

Mine has been replaced with a modified one. The people remove the original and replace it with a marine grade aluminium tube. So I was informed. Also it is not so much a cooler more a heater for the cold countries. Cost? $440.

Can find out more if required.

Tony :wheelchair:

[Redback]

Mine has been replaced with a modified one. The people remove the original and replace it with a marine grade aluminium tube. So I was informed. Also it is not so much a cooler more a heater for the cold countries. Cost? $440.

Can find out more if required.

Tony :wheelchair:

Yes please, just for peace of mind, mine is getting up in Ks and I feel it won't be long:(

Baz.

[Hendrik]

Mine has been replaced with a modified one. The people remove the original and replace it with a marine grade aluminium tube. So I was informed. Also it is not so much a cooler more a heater for the cold countries. Cost? $440.

Can find out more if required.

Tony :wheelchair:

Please do, I would really appreciate it. Yeah have a look at it Baz, mine went without warning, thank goodness I wasn't driving it at the time, otherwise it would have been way worse.

[Freddohd]

Mine has been replaced with a modified one. The people remove the original and replace it with a marine grade aluminium tube. So I was informed. Also it is not so much a cooler more a heater for the cold countries. Cost? $440.

Can find out more if required.

Tony :wheelchair:
Hey Grumpy,
Where did you get a quote for $440? Does this include labour? On the cap of my expansion vase I think I can feel a slight oily film. Should I wait till I see some creamy residue or get the oil cooler changed now?
Thanks for your replies

[Hendrik]

Thats a sign that it is on its way out, mine did the exact same thing. I'd get it looked at, before it goes.

[Redback]

Please do, I would really appreciate it. Yeah have a look at it Baz, mine went without warning, thank goodness I wasn't driving it at the time, otherwise it would have been way worse.

I have looked at recently, I cleaned it after I upgraded my Intercooler, looked fine, clean and free of mud and dirt and I check the coolant on a regular basis too, for signs of oil as well as coolant level.

It's a just in case thing, as we do a lot of long distance touring towing a heavey camper, don't want to be stuck in the middle of nowhere.

Baz.

[Hendrik]

Well pulled out the oil cooler, lots of electrolysis, pressure tested it and refitted it. Was good at first, but then after a few drives, the coolant was non existant and a lot of grey oil in its place. So I guess it is time for a new oil cooler...then a new water pump, then a new radiator, then the fuel pump will probably go...does it ever stop???

[George130]

Mine ws replaced with a custom made one. Cost me $150. It was made from marine grade aluminium like grumpys but was not a tube but a box the same size as the original one, No fins but better flow.

[LandyAndy]

Edd and Grumpy.
Any pics or more info on these non genuine coolers???
Once my driveline overhaul is done,Im replacing the radiator,intercooler,waterpump viscous fan and oil cooler.
Saving $$$ and upgrade of the cooler would be great!!!
Andrew

[Hendrik]

Well my oil cooler has come off 4 times now in a week. I am amazing at removing it now, got it off in 20min this afternoon :D The last time I finally managed to get the oil out of the coolant, but then I saw a water leak on the side of the engine. Turns out a bit of oil leaked over the gasket and sealant and it didn't seal properly. It will be fine now, went through extra effort to make sure everything is sealed this time.

For now I am reusing the old matrix and casing. The matrix was a bit of a victim of electrolysis, my fault as I ran the car for ages with a low coolant concentration...which is a big no no. On the matrix, the casing around the o-rings were chewed out and the o-rings failed as well. So I cut two steel rings from some pipe, and placed them around the port casings on the matrix for a very tight fit. This going against my, do it once do it properly philosophy, but I need to get this car back on the road...its been 6 months now of endless troubles.

[Dazza67]

Mine blew a month ago exact same grey sludge in the coolant system, replaced with genuine from rovercraft total inc a minor service and labour $1700, the wife is only just talking to me now after a month!

[George130]

Edd and Grumpy.
Any pics or more info on these non genuine coolers???
Once my driveline overhaul is done,Im replacing the radiator,intercooler,waterpump viscous fan and oil cooler.
Saving $$$ and upgrade of the cooler would be great!!!
Andrew

I was not that clever. Wish I had got pictures.
If you look in there you will see it is not hard to build a replacement. We were also considering fitting an external oil cooler at the time.

The cooler is attached by 2 banjo bolts to the inside of the housing.

[Hendrik]

So did you just go to a radiator place and get one made up? I will need a new one now, I've had it off 4 times now and only just realised it :o
It is a pretty simple cooler, it wouldn't take much to make a new one I think.

[Dazza67]

Wish I had got pictures.


This is a pic of my cooler when it came out, 2 nice cracks in it under pressure test, I can take better pics if you want.

[George130]

So did you just go to a radiator place and get one made up? I will need a new one now, I've had it off 4 times now and only just realised it :o
It is a pretty simple cooler, it wouldn't take much to make a new one I think.

No. It was done through a friend. They should be easy to get one made up.