2004-2007 F250 & F350 6.0L EGR Coolers

2004-2007 F250 & F350 6.0L EGR Coolers: More Information

Ah, the notorious EGR cooler; one of the 6.0's many weak spots and the source of many hours of frustration and mechanic bills. The 2003 Super Duty launched with a round EGR cooler which ironically turned out to be more efficient and far less prone to failure than the square EGR cooler that would replace it in the 2004 model year.

While the 2003 round EGR coolers fared better in terms of reliability, they still left a lot to be desired. The design's internal fins were restricting exhaust flow and causing build-up which led to blown coolers and further issues down the line. With the introduction of the square cooler for the 2004 and up models, things only got worse.

The square version of the 6.0L EGR cooler featured the same problematic internal design, only this time contained in an even smaller, rectangle assembly. Obviously, this didn't do any favors for reliability and the redesigned EGR cooler turned out to be more trouble than it was worth. Thankfully, the aftermarket has come to the rescue with both square and round EGR coolers for the 6.0L Powerstroke. The only thing is that you need to check your build date to figure out which cooler you need. The vast majority of trucks with build dates before 9/22/03 are only compatible with the original EGR cooler with the round design. If your truck was built after that date, you'll most likely need the square version from 2004+ models. To be absolutely certain that you get the right cooler for your truck, you'll have to inspect your EGR system to see whether your truck came equipped with the original round cooler or the redesigned square cooler.

Our aftermarket EGR coolers all feature one game-changing improvement over the factory components: larger, tubular passageways in place of the factory finned design that restricted exhaust flow and caused soot build-up and eventual failure. Any one of our upgraded aftermarket EGR coolers will vastly improve reliability and prolong your EGR system's life.

It's important to note that an EGR cooler alone will not solve every problem in your 6.0, although it is definitely a good start. If you're looking for a more conclusive fix, you'll need to address the issue of inefficient oil filtration, which is often the root problem to blame for clogged and blown EGR coolers. We carry a comprehensive oil/coolant filtration kit by Sinister Diesel with everything you'll need to address your oil filter and oil cooler, which combined with a new EGR cooler should take care of most of the issues with your EGR system.