The diesel engine uses a compression-ignition system, meaning that it uses the heat of compression to initiate a spark-ignition to burn the air-fuel mixture.  Using this style of internal combustion has it advantages and disadvantages.  The diesel engine has the highest thermal efficiency of any combustion engine using this method of heat along with high compression ratio for better efficiency.  This also is it’s weakness, due to the amount of heat the engine as to deal with.  That is why the diesel engine requires a EGR Cooler, needing to cool the recirculation of the exhaust gasses to maintain a acceptable operating temperature while  complying with federal emissions standards.

How does a EGR Cooler work?  The exhaust gasses are directed through the Exhaust Gas Recirculation (EGR) System Cooler to remove heat before the exhaust gasses arrive at the EGR valve.  This system uses engine coolant to reduce the exhaust gas temperature entering the intake.   Unfortunately this system deals with extremely high temperatures which fatigues the metal components causing cracks.  Which seems to be a common problem on most diesel engines.  For example on the Ford Power Stroke 6.0L Turbocharged Diesel you don’t even know there is a problem, just a slow coolant loss.  At first you may notice just a loss of coolant with no leak.  As this condition gets worse, you’ll see white clouds of smoke from the exhaust pipe.  This is the coolant leaking through the cooler into the intake and vaporizing, exiting out the exhaust pipe.

APDTY now offeres a solution for the EGR cooler problems with a redesigned EGR cooler that has a larger tubing design instead of the original small fin designed (similar to a radiator).  This new cooler is re-manufactured and improved by removing the factory fin design and replaced with bigger thicker stainless steel tubes that allow the exhaust gas to cool without the chance of cracking & mixing with coolant which is the main cause of failure on the factory original units.

2010-05 Ford 6.0L Diesel EGR Cooler Tubular Upgrade

With the 6.0L Power Stroke, another problem leading up to the EGR cooler failure is often the oil cooler.  Coolant first flows through the oil cooler before the EGR Cooler, this oil cooler is know for plugging up and restricting flow to the EGR cooler.  Without the coolant flowing the engine temperatures will become extremely hot, starting a pattern of overheating failures with the EGR cooler and engine oil temperatures.  This could eventually lead to failures of the oil pump, fuel injectors and turbocharger problems. A tale-tail sign of your oil cooler going bad is coolant boiling out of the overflow bottle.  We also carry and recommend the factory original Ford Oil Cooler repair kit, part # 3C3Z6A642CA to be replaced at the same time as the cooler.

FORD OEM Part Number 3C3Z6A642CA

Replacing the EGR Cooler requires that the turbocharger and intake manifold be removed.  To make this replacement easy,  Apdty offers several other parts related to repairing the Ford Super Duty 6.0L Turbo Diesel EGR Problem.

Ford OEM EGR Cooler/Intake Gasket Kit for the 6.0L  Turbo Diesel.

2004-2009 Intake Manifold 5C3Z-9424-A

Dorman Products offers a Turbo hardware kit including the o-rings, gasket and bolts needed for doing this job.  Dorman part number 904-234.