Solved: Full Blown Motorsports Oil Cooler Leak (Pics and Video)
 

So I ordered this oil cooler kit from ft86speedfactory.com for my 2015 FRS in December.

http://www.ft86speedfactory.com/full...l#.Wm4nVqinFhE

https://i.imgur.com/BJtseKF.jpg

I was able to install it without much problem using the provided instructions, and it worked fine for daily driving and spirited mountain driving for about a month since then. But then I took it to a track day at Mazda Laguna Seca...

After the first 20 minute session I took a paper tower and checked all of the connections for oil leakage. All of the threaded points, on both the cooler and the sandwich plate, were holding tight with no signs of oil leak. However, there was a very small amount of oil seeping past the gasket between the sandwich plate and the spacer. The amount was extremely minor, a smudge of oil visible on the paper towel.

After the second session I found that the leak had become much more significant. A larger amount of oil had pushed past the same gasket and had splattered around the inside of the engine bay. I cleaned up the oil and checked the oil level of the engine. The oil level of the engine was not noticeably affected. I used an oil filter wrench to tighten down the oil filter in the hopes that it would help stop the leak. I noticed that even after tightening the filter, I could rotate the sandwich plate with a moderate amount of force.

After the third session the leak was the same. More oil splattered around the engine bay. I removed the oil filter and inspected all of the gaskets: One on the underside the the spacer, one under the sandwich plate (this appeared to be the source of the leak) and one on the oil filter. All appeared normal with no obvious sources of the leak. I reinstalled the parts and used a wrench to tighten the pipe piece with screw that holds the sandwich plate down onto the spacer. I then screwed the oil filter back in place, hand tight.

After the fourth and fifth sessions the leak was still the same, each time with new oil in the engine bay. The oil level in the engine remained not noticeably affected. I cleaned the engine bay of oil after each session.

After driving home, approximately 2 hours, (not pushing the engine) there was new oil spattered around the engine bay.

So I talked to FBM and they said they have had some issues with some spacers, so they sent me a new spacer and O-rings. I put them on, putting a bit of torque on the center bolt with a wrench and hand tightening the filter. I started up the car, and guess what: The leak is way worse. I left it idleing and watched oil slowly drip out of the space between the sandwich plate and spacer. Here's video and a picture.

[ame="https://www.youtube.com/watch?v=D4mjG_9Ml0Q"]2015 FRS Full Blown Motorsports Oil Cooler Sandwich Plate Leak - YouTube[/ame]

https://i.imgur.com/UQeVh3n.jpg

I talked to FBM on the phone and they seemed to have no idea what to do, which is.... disappointing.

Anyone have any ideas on how to fix this?

Solution

After working with FBM I was eventually able to fix this problem, and now the cooler has stood up to a couple months of daily driving, some spirited mountain driving and a track day without issue. See my posts for more detail and oil temp data.

Following. I was about to order this.

Inspect both sides for gouges. Is the extension fitting too long? Bottoming out?

Is that a mocal plate & adapter?

Did you try putting a little bit of oil between the sandwich plate and spacer to get a better seal?

Bubba says to put some "Permatex" (he's old school) on all the mating surfaces.

If that don't stop the leak, he suggests you take that sandwich plate and that other plate/spacer off and have them machined to make sure they ain't warped.

Bubba has spoke .......:D

Both sides of what? I searched all around the sandwich plate and spacer for any sign of why it's leaking, but everything looks fine. All surfaces around the gaskets look smooth, there are no gouges that would cause a leak. Ill post more pictures.

As far as the extension fitting, do you mean the center bolt? Everything looks like it fits right.

Yes it is a Mocal sandwich plate. By adapter do you mean the spacer below the sandwich plate? Not sure who makes that part.

I did make sure to oil all the gaskets before putting it together.

Hmmm... Interesting idea

Here is the first spacer. It looks identical to the replacement one they sent.

https://i.imgur.com/2HY2Myn.jpg

Center bolt and top side of sandwich plate

https://i.imgur.com/YJhtZ76.jpg

Bottom side of sandwich place with original o-ring. When I closely inspected this, the o-ring did not have any cracks or binds.

https://i.imgur.com/P6xU4Qk.jpg

Bottom side of original spacer with original o-ring

https://i.imgur.com/Tk46jr0.jpg

The scene of the crime!

https://i.imgur.com/ecZMvzw.jpg

Your car's engine is "rejecting" the oil cooler .......:sigh:


humfrz

Wonder if the two sealing surfaces are not parallel. I know you are probably tired of messing with this but start it up, mark where it leaks, rotate the spacer, and see if it leaks in the same spot. Check with calipers or micrometer. With the o-rings you would think it would have to be pretty far off. But with the center bolt holding it, it may not allow enough deflection for the o-rings to seal if it is off by a significant amount.

Why does the top side of the sandwich plate look like it's cast but not machined smooth?

Good point!! Those wrinkles could have a lot to do with it. Also is the seal on your oil filter smooth now or nicks in it due to the sandwich plate?

I had a small leak that got worse overtime on a different oil cooler. Turns out if the oil leaks like that, it allows the center bolt to loosen up over time. I overtorqued it a little more this time and hasnt leaked since. Did you check how tight it was when you pulled it off?