Oil cooler header concern

[OldIron82]

Hey all. What do you make of this corrosive damage here? Could this be from electrolysis due to a bad ground when the engine was in the previous owners truck? I think it's too deep for silicone to be of any use due to the depth of the pitting and the pressure of the cooling system pushing on it. If I had any aluminum shielding gas I could weld it full again then grind/sand it smooth. I suppose I could JB WELD it then use a gasket and silicone...or look around for another cooler...or just swap the entire assembly off of the 7.3 in the truck right now that I rebuilt when i swap in the 6.9

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[chris142]

Bad acidic coolant done that.

 

[Thewespaul]

Wow I’ve never seen one that bad

 

[nostrokes]

Wow if the cooler header is that bad I wonder what the rest of the system looks like


I'd just replace it... Welding and grinding might warp it too bad to seal again and we all know what JB weld is really good for...

 

[Dieselcrawler]

I have two clean, beadblasted headers ready for ya if you need them. Front and rear, no tube. 100 bucks for both

 

[OldIron82]

Depending upon what the general consensus on this is I may take you up on that. The oil cooler headers off the ambulance 87 6.9 which had the ice destroyed cylinder walls ( I've had so much luck trying to build a 6.9 ) I chipped the damn rear header right where that little groove lock is when I took it apart. I have the cooler chamber rotated down as far as it will go before it stops again. From my experience with these they do not rotate easily when fully assembled so but even if they did it can't go lower than this. I can't imagine it's that critical. The internal holes are 12oclock and 6o'clock respectively but this being slightly passed that it's still almost where it's designed to be. I can't see it effecting its performance at all. What you think? Clean it up and run it or toss it?

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[IDIBRONCO]

I'd clean it, put new o-rings in, and run it. It should be fine. I'm not sure that the tube moves at all after it's assembled. I could be wrong, but I've always assumed that the grooves are to help get the caps lined up close when reassembling the oil cooler.