Is there any way to check a oil cooler? I removed it and used a plate to air presser test it. I flushed cooland system 4 times 2 diffrent times with dawn. It had some oil in lower hose that came out first time i drained it and now it has some in coolant tank.After 1 cleaning coolant tank had junk in it that looked like bars leak stop. Its a PX 8 paccar 315 that was bought this summer from a dealer.
Don't use a detergent that will foam to flush an engine, I use Cascade dishwasher powder mixed pretty stiff, pull the thermostats and reinstall the housing. For an engine that size I use 5 pounds of powder dissolved in hot water pour that into the rad and follow with more hot water til full. Run the engine with the fan disabled or cover the radiator to keep it a 195-200 degrees for at least an hour. After that shut it down and dump it at 140 degrees and refill with hot water and circulate another hour, dump that at 140 degrees and watch for a "rainbow" in the drain water, pull the t-stat housing and wipe your finger in there looking for oil residue.
I have used 15 pounds in a really bad 3406E where the coolant came out looking like chocolate mousse. One trip at 15 pounds cleaned it right out the first time.
Did the pressure plate test show a leak? did you submerge it in HOT water to look for bubbles?
Oh and if possible, eliminate the surge tank while flushing. It just collects crap and doesn't contribute to the flush procedure.