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6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van SPONSORED BY:

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  #1  
Old 11-01-2012, 10:46 PM
kelleyboy kelleyboy is offline
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Unhappy 2004 F250 6.0 EGR cooler failure

My truck has 111,000 mi. and suffering from the second EGR cooler failure. Is the Bullet




















































Truck has 111,ooo mi. and plagued with the second EGR cooler failure. Question: Is the Bullet Proof products as good as they advertise?? What path should I take, sell or fix and how much can I expect to spend if I decide to get repairs made?
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Old 11-01-2012, 10:59 PM
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have you been changing the oil cooler too???
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Benny oem hpop 1/8/14,update ipr screen
2003 6.0, 4X4 srw, short box, born on 3/28/03 Moog ball joints,DC POWER 190A ALT Duralast Goldtop batterys 10/7/2012,RECON LED SMOKE MIRROR LENS,4 inch turbo back magnaflo exhaust,no kitty, 6 in. lift, BFG 315/75r16, python remote start alarm,pioneer system2 12''subs 1600watt amps ,scangaugeII,coolant filter, blue fuel pres spring, Fresh oil cooler 6/1/11 Final Charge Cat EC-1 rated Silicate Free ELC coolant, Sinister Full egr deleate, ROTELLA T-6 5w-40syn,updatedHPO screen,updated oil filter stand pipe, TC SX8000
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Old 11-01-2012, 11:18 PM
kelleyboy kelleyboy is offline
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EGR cooler failure

The first EGR cooler failure was covered under warranty at 55,000 mi. I assume Ford products were used but not replacement of oil cooler. Now 55,000 miles later another failure, and my question is can I find quality products to repair this vehicle or should I sell this truck and not look back.
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Old 11-01-2012, 11:23 PM
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the ROOT PROBLEM is the OIL COOLER so replace it too

the Oil Cooler Plugs and starves the egr cooler for coolant at this point EGR Cooler burns up

also install a coolant filter

do a thuro coolant flush to

then you will be good

If you dont replace the oil cooler the egr coolers will keep failing
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Benny oem hpop 1/8/14,update ipr screen
2003 6.0, 4X4 srw, short box, born on 3/28/03 Moog ball joints,DC POWER 190A ALT Duralast Goldtop batterys 10/7/2012,RECON LED SMOKE MIRROR LENS,4 inch turbo back magnaflo exhaust,no kitty, 6 in. lift, BFG 315/75r16, python remote start alarm,pioneer system2 12''subs 1600watt amps ,scangaugeII,coolant filter, blue fuel pres spring, Fresh oil cooler 6/1/11 Final Charge Cat EC-1 rated Silicate Free ELC coolant, Sinister Full egr deleate, ROTELLA T-6 5w-40syn,updatedHPO screen,updated oil filter stand pipe, TC SX8000
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Old 11-01-2012, 11:24 PM
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read thru this

http://api.viglink.com/api/click?for...13518266640081
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Benny oem hpop 1/8/14,update ipr screen
2003 6.0, 4X4 srw, short box, born on 3/28/03 Moog ball joints,DC POWER 190A ALT Duralast Goldtop batterys 10/7/2012,RECON LED SMOKE MIRROR LENS,4 inch turbo back magnaflo exhaust,no kitty, 6 in. lift, BFG 315/75r16, python remote start alarm,pioneer system2 12''subs 1600watt amps ,scangaugeII,coolant filter, blue fuel pres spring, Fresh oil cooler 6/1/11 Final Charge Cat EC-1 rated Silicate Free ELC coolant, Sinister Full egr deleate, ROTELLA T-6 5w-40syn,updatedHPO screen,updated oil filter stand pipe, TC SX8000
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Old 11-01-2012, 11:30 PM
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you also need to get a gauge and watch ECT vs EOT no more than 15* spread

there are a few rules to taking the temps at the right time so get a gauge and Study up that link above


welcome to FTE

your truck will be fine it just needs to be fixed right


How do you know it the EGR Cooler and not an Injector issue???

you are probably corect to assume a EGR Cooler problem from the sounds of how the repairs went down I just want to be shure I send you down the right path

So are you losing Coolant and white smoke???????
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Benny oem hpop 1/8/14,update ipr screen
2003 6.0, 4X4 srw, short box, born on 3/28/03 Moog ball joints,DC POWER 190A ALT Duralast Goldtop batterys 10/7/2012,RECON LED SMOKE MIRROR LENS,4 inch turbo back magnaflo exhaust,no kitty, 6 in. lift, BFG 315/75r16, python remote start alarm,pioneer system2 12''subs 1600watt amps ,scangaugeII,coolant filter, blue fuel pres spring, Fresh oil cooler 6/1/11 Final Charge Cat EC-1 rated Silicate Free ELC coolant, Sinister Full egr deleate, ROTELLA T-6 5w-40syn,updatedHPO screen,updated oil filter stand pipe, TC SX8000
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Old 11-02-2012, 07:41 AM
kelleyboy kelleyboy is offline
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yes losing coolant, smoking, liquid out exhaust. Truck does not use oil, seems to be very solid except for above listed issues. Thanks for your help.
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Old 11-02-2012, 08:08 AM
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Do you know if your EGR cooler is the one with fins or tubes for internal components?
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Old 11-03-2012, 09:32 AM
kelleyboy kelleyboy is offline
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Which oil cooler should I go with: reluctant to buy Ford,,is there an aftermarket oil cooler that you would recommend? How about EGR delete?
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Old 11-03-2012, 02:52 PM
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Keep in mind these Oil Cooler Fail 2 diffrent ways.
1. Plugged Coolant Paths in Oil Cooler
2. A Manufacture assembly issue/Internal Breach what mixes Both Coolant & Oil together

once you clean the cooling system and get a coolant filter the OEM Oil Coolers been fine
I Plugged a OEM oil Cooler 1.5years ago in mine I flushed Very well and Ran a coolant filter for a couple months before I changed the OEM Oil Cooler I have around 15K since and My Delatas are still Good

I also run ELC thats Silicate Free it seams to help the Coolant filters Go Longer
There is Some Debate that the OEM Gold Coolant causes the Issues with plugged oil coolers I Cant say it Does or Does Not However my coolant filters do Last longer FWIW

Also Keep in mind By Deleating the EGR Cooler shure you eliminate that part BUT you still must watch the temps for the Oil Cooler

I did go a EGR Deleate on mine But Not for any reasons mentioned here or because of the issues you Have Now



However if you want to spend some money there are other options


Here is the one I kinda like its from IPR its a OEM Oil Cooler relocation kit and Inline filter it willl filter at 100% of the coolant going to the Oil Cooler. Its $$ 1300.00

IPR External Oil Cooler Kit for Ford 6.0 Powerstroke


Here is the BPD option its a total removal of the OEM Oil Cooler and then uses a air to oil cooler up in front of the truck. It removes the Risk of the either of the two ways these oil coolers fail. However its the most money around $$ 2200.00

BulletProof Engine Oil Systems
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Benny oem hpop 1/8/14,update ipr screen
2003 6.0, 4X4 srw, short box, born on 3/28/03 Moog ball joints,DC POWER 190A ALT Duralast Goldtop batterys 10/7/2012,RECON LED SMOKE MIRROR LENS,4 inch turbo back magnaflo exhaust,no kitty, 6 in. lift, BFG 315/75r16, python remote start alarm,pioneer system2 12''subs 1600watt amps ,scangaugeII,coolant filter, blue fuel pres spring, Fresh oil cooler 6/1/11 Final Charge Cat EC-1 rated Silicate Free ELC coolant, Sinister Full egr deleate, ROTELLA T-6 5w-40syn,updatedHPO screen,updated oil filter stand pipe, TC SX8000
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Old 11-03-2012, 03:41 PM
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I know Alot of this^^^ was on Oil Coolers but you must address the ROOT Cause of the EGR Cooler failure

Also might be worth finding a shop that little better with 6.0L
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Benny oem hpop 1/8/14,update ipr screen
2003 6.0, 4X4 srw, short box, born on 3/28/03 Moog ball joints,DC POWER 190A ALT Duralast Goldtop batterys 10/7/2012,RECON LED SMOKE MIRROR LENS,4 inch turbo back magnaflo exhaust,no kitty, 6 in. lift, BFG 315/75r16, python remote start alarm,pioneer system2 12''subs 1600watt amps ,scangaugeII,coolant filter, blue fuel pres spring, Fresh oil cooler 6/1/11 Final Charge Cat EC-1 rated Silicate Free ELC coolant, Sinister Full egr deleate, ROTELLA T-6 5w-40syn,updatedHPO screen,updated oil filter stand pipe, TC SX8000
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Old 05-29-2014, 07:36 PM
Harrier and Ford guy Harrier and Ford guy is offline
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oil cooler failure / coolant flush

Need some advise. Have gray milk shake consistency fluid in the coolant tank of my 2004 6.0. I am assuming a oil cooler failure. (Made it to 100,000 miles before it failed). If so how do you clean the cooling system as if you do it with the old cooler installed would it not continue to leak oil into the coolant? If I do it after I repair it, will I not contaminate the new cooler or if I put a after market cooler on it, will I not contaminate the new EGR cooler?
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Old 05-29-2014, 07:36 PM
 
 
 
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