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Mustang S550 5L V8 GT RHD: Oil Cooler leakage problem:

Madstang

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Mustang S550 5L V8 GT RHD: Oil Cooler leakage problem:
Can anyone help on a definitive answer for fixing the oil cooler leakage problem - oil into water and vise versa (V8 disaster),and oil onto exhaust (fire) ?
There are conflicting dates concerning which vehicles are affected - Ford Parts Info suggest June (and August) 2016 - 2 coolers exist for RHD (is the later one a fix for this ?). There is a Tech. Service Bulletin raised 14th June 2019 which says builds on/before Feb 2017 affected. I have heard of a failure on a May 2017 build.
Rumour has it the problem stems from the packaging conversion to RHD, where the exhaust downpipes run very close to the cooler, overheating it . Just replacing the cooler won't solve this (maybe needs a heatshield) - or is it just a batch of faulty coolers ?
Any info would be welcome ...
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Twin Turbo

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Hi Paul

Seems to mainly effect the pre-facelift models, but I'm pretty sure I've heard of at least one '18MY that suffered as well. And, yep, it's thought to be due to the closeness of the cooler to the exhaust (which was modified on the '18).

Mustang specialist Modurstang has a preventative alternative oil cooler that a number of owners have had fitted.

Has your car suffered or are you just doing your homework?
 

kaiser_sosai

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Mustang S550 5L V8 GT RHD: Oil Cooler leakage problem:
Can anyone help on a definitive answer for fixing the oil cooler leakage problem - oil into water and vise versa (V8 disaster),and oil onto exhaust (fire) ?
There are conflicting dates concerning which vehicles are affected - Ford Parts Info suggest June (and August) 2016 - 2 coolers exist for RHD (is the later one a fix for this ?). There is a Tech. Service Bulletin raised 14th June 2019 which says builds on/before Feb 2017 affected. I have heard of a failure on a May 2017 build.
Rumour has it the problem stems from the packaging conversion to RHD, where the exhaust downpipes run very close to the cooler, overheating it . Just replacing the cooler won't solve this (maybe needs a heatshield) - or is it just a batch of faulty coolers ?
Any info would be welcome ...
Hi Paul,

There is quite a lot of discussion about this in the Australian section. Read this thread if you haven't seen it.
https://www.mustang6g.com/forums/threads/oil-cooler-failure-first-hand-experiences.90359/

I have a June 2017 GT RHD, and I read quite a bit about the issue before I made my purchase. At the end of the day, it was either buy one of the last affordable V8s and live with the possibility of a cooked engine, or don't.
My summary of the information is as follows (in no particular order):
  • I think we can disregard what Ford are saying in TSBs. Car manufacturers don't have our best interests in mind. The issue appears to affect ALL 2015 - 2017 RHD GTs. Though it does seem the earlier the build date the more likely the issue.
  • It would appear to be a design issue with RHD. Initial owner speculation was due to cooler proximity to the catalytic converter and failure due to higher operating temperatures. However, there is some doubt regarding this. For example, stretching the memory, I seem to recall reading about an Australian engineering firm that produces a replacement cooler claim to have carried out testing and believe it is due to a pulsating oil pressure phenomenon or some such.
  • Cooler failure is either external leak, internal leak, or both.
  • 2018+ RHD models don't seem to be affected from a design point of view. I've heard of some failures, but it's possible these fall within the realms of standard component failure rates. I have no quantifiable data to support that hypothesis however. 2018+ does seem to have other weaknesses though.
  • For in-warranty claims, Ford seems to resolve cooler failures with the following resolutions depending on cooler failure scenario:
    • Replace failed cooler with new unit (presumably a unit that is similarly affected and may see a repeat failure)
    • Replace the engine (and failed cooler).
  • Some owners have had multiple failures.
  • There is concern over out-of-warranty claims.
  • Failures are random in nature. Do not appear to be consistent with climate or driving type. Some fail on highway at low RPM, others at traffic lights when pulling away, some go bang, others develop a leak noticed in garage/driveway.
  • Most of the owner concern isn't that there is a design flaw or faulty part leading to a problem (this is common on any product). It is that the failure is catastrophic, totally unexpected, and can be fairly dangerous e.g. failure resulting in power loss and potential collision...or engine fires (my favourite).
  • There are a number of quality third party oil to air cooler solutions available - Mishimoto, and two aussie companies I know of Harrop, and Streetfigher. It would appear these are far better coolers generally.
  • Seems like some owners are taking the risk until the end of warranty, then having one of these aftermarket options fitted. Taking the risk in case other issues arises where warranty may be denied by Ford due to 'modification'. Count myself as one of these owners.
And lastly, all has been pretty quiet on the cooler failure front for a while. Perhaps it was a bad batch of oil coolers...you know from 2015 to mid 2017. 2.5 years out of a 3 year lifespan [1 out of 6 ain't bad eh?]. This also makes no sense to why LHD cars weren't affected.
There's quite a few guys and gals on the Aussie local section with first hand experience(s). They might have better insight or disagree with some of my interpretations of the info I've come across.

Anyway, hope that summary helps with any remaining questions you have.
 
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Madstang

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Hi Paul

Seems to mainly effect the pre-facelift models, but I'm pretty sure I've heard of at least one '18MY that suffered as well. And, yep, it's thought to be due to the closeness of the cooler to the exhaust (which was modified on the '18).

Mustang specialist Modurstang has a preventative alternative oil cooler that a number of owners have had fitted.

Has your car suffered or are you just doing your homework?
Thanks for reply. Forgot to mention, my car was built May 2016, has done 21,000 miles, and is only showing a 'discolouration' around one of the oil cooler pipes - not sure if its about to leak. (no water contamination yet).
The air cooled oil cooler looks a good option (saves engine), but I was trying to find out If Ford have a solution yet. Does anyone know the difference with the facelift 2018 cooler ?
 

maddog1982

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v8hgt

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In the U.K. there is an option using a kit developed by Nemesis and fitted by GT101 (maybe modurstang too). It appears to be the best option for our climate as it’s air/oil with a thermostat using what looks like a Setrab cooler. Price inc fitting and vat is approx £950. Mine is going in for it in a couple of weeks time. I will post fitting pics of mine when the work is being done. GT101 have some detail on their Facebook page:
 
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Tom.GT

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*sets reminder to check oil & coolant for signs of mixing every week*

Build date 05/2016 😬 don’t have a spare grand currently...
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