1983 6.9 engine oil cooler bypass kit?

AZBLACKSMOKE said:

Thank you. Can you tell me what year van you had? I looked at ones for an 86 E350...but the pictures look identical to the truck ones....at least on the Dorman site.

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All 1983 to 1991 diesel vans, at least, are verified to use the different exhaust manifold, oil cooler and motor mount. The van mount on the passenger side is also a bit different, but the exhaust is identical to the pickup.

Personally, I can vouch for 1983 to 1989 E250/350.

The pickup manifold, cooler and mount simply will not fit in the van - and I tried before I noticed, the first time around some years back.

Now, I don't know what the clearance issues are on your 79 Dump Truck. But the components for the vans are placed considerably lower down on the block, reducing width at the top on the driver side, to fit the dog house. Maybe if you give us a picture of the interference issue, it could help. I may have some pictures from a recent swap that show what that side of the engine looks like for the van application.

I was thinking they were closer to the block but after the last post on pretty sure they do sit lower on the block and the oil filter points slightly toward the rear instead of straight down like a truck


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Here's a 93 7.3 IDI from a pickup, being prepared to install into an 83-91 van. The manifold, cooler and mount all had to be swapped for the van versions.



BTW, the swap was done by one person in a home garage with no help...

On our trucks the drivers side exhaust manifold is an upsweep type and the passenger side is a downward sweep manifold. The Van manifold turns down differently than the truck manifolds on the drivers side. the passenger side is the same truck or van. As already posted the coolant inlet and outlet flanges are different on the S1600 big trucks like what you are working on.

VanDiesel said:

All 1983 to 1991 diesel vans, at least, are verified to use the different exhaust manifold, oil cooler and motor mount. The van mount on the passenger side is also a bit different, but the exhaust is identical to the pickup.

Personally, I can vouch for 1983 to 1989 E250/350.

The pickup manifold, cooler and mount simply will not fit in the van - and I tried before I noticed, the first time around some years back.

Now, I don't know what the clearance issues are on your 79 Dump Truck. But the components for the vans are placed considerably lower down on the block, reducing width at the top on the driver side, to fit the dog house. Maybe if you give us a picture of the interference issue, it could help. I may have some pictures from a recent swap that show what that side of the engine looks like for the van application.

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Ive been so swamped today, I haven't had a chance to do much research or mockup, but I did take some pics of the clearance issues Im having. The passenger side is a definiatly a no go, but I think I can massage the drivers side exhaust in ok. The lower radiator hose outlet is hitting the oil cooler, but Im redoing my radiator and I think I'll be able to use the stock f250 outlet....I still need to get the air compressor for the air brakes on, and the other accessories, but I don't think I'll have an issue. The passenger side exaust manifold and bell housing is the biggest issue at this point, but im not worried. Ill skin this cat one way or another. Thanks for the info...you guys are very helpful. Here are some pics of my issues.

icanfixall said:

On our trucks the drivers side exhaust manifold is an upsweep type and the passenger side is a downward sweep manifold. The Van manifold turns down differently than the truck manifolds on the drivers side. the passenger side is the same truck or van. As already posted the coolant inlet and outlet flanges are different on the S1600 big trucks like what you are working on.

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The passenger side is my issue. So then you're saying the passenger side manifold are the same on both vans and trucks? What about a 7.3 S series? Im hoping they will work if I can find one. Maybe an old U-Haul truck. The drivers side I think itll clear...barely. The water outlet interferes, but Im pretty sure I can use the truck outlet and redo the radiator...im looking at a custom built one. It needs replaced anyway..the original 446 radiator is corroded and has been repaired many times.

Not sure what exhaust manifold fits the S sreies rigs but I recall it might be the drivers side turned around so it dumps exhaust from the front on the block. another thing not mentioned yet is the oil pan must be turned around so the sump is in the fron of the engine. that means you will need a different oil pickup too. I believe the truck oil pan is just turned around but don't quote me on this. It maybe wrong.

icanfixall said:

Not sure what exhaust manifold fits the S sreies rigs but I recall it might be the drivers side turned around so it dumps exhaust from the front on the block. another thing not mentioned yet is the oil pan must be turned around so the sump is in the fron of the engine. that means you will need a different oil pickup too. I believe the truck oil pan is just turned around but don't quote me on this. It maybe wrong.

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IIRC I can't turn it around because it interferes with the oil cooler. I already tried. Maybe a combination of the correct manifold, van cooler, etc. I'm still working on it. I'm kinda looking into making my own headers...but we'll see. I'm exploring all options.

I check the oil pan and should have plenty of clearance. I have the front horseshoe type motor mount and then the 2 rear bellhousing mounts. So my clearance under the pan is good.

I also seem to recall that one exhaust manifold dumps out the front, but can't remember which one. Just find the right ones for a S series. I believe the van and International oil cooler headers were the same. The actual cooler tubes are the same. They do sit a little closer to the block and need to use the bolts for the right application. Of course you can just buy new bolts. The oil pan is different between the Ford and International applications. You can see the difference if you look at the pans or pictures of them. I think that the International oil pan holds more oil which makes sense because it's used in a medium duty truck instead of a light duty one like our Fords. The motor mounts in your description are the right ones for the International application. I do know that the 6.9 was used in the S series trucks as well as the 7.3 because I've swapped two of them out so the parts are out there somewhere.

idiperformance.com sells both exhaust header 'strips' that you can build your own manifold with, and entire fabbed manifolds.

S series exhaust, driverside dumps Straight down, The pass side dumps close to the middle and straight down also. The oil cooler is much different. Either you need to find the correct parts from a s series or get creative

This looks just like the 83-91 driver side of E250/350 van application: exhaust, cooler, motor mount upper.

Dieselcrawler said:

S series exhaust, driverside dumps Straight down, The pass side dumps close to the middle and straight down also. The oil cooler is much different. Either you need to find the correct parts from a s series or get creative

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I have a new medium duty engine sitting here.
I know the cooler and pan and oil pickup tube are different . also fuel filter and such. If it has exhaust manifolds on it I would make you a package deal on the parts. Ill know more this afternoon, its at work and I have to go in.

typ4 said:

I have a new medium duty engine sitting here.
I know the cooler and pan and oil pickup tube are different . also fuel filter and such. If it has exhaust manifolds on it I would make you a package deal on the parts. Ill know more this afternoon, its at work and I have to go in.

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From the looks of it if everything else fits, only the exhaust, cooler and motor mount from the van style need changing. Any of the fuel filter styles will work.

Yea I wasn't paying attention when looking for pics. That one came up during a search. I did not have a chance to get to the yard to get proper pics