My '04 Diesel has been diagnosed with two blown head gaskets, blown EGR valve and EGR Filter....was hoping you guys could help:

1. Has anyone replaced these parts on their own, any difficulties, any tips?
2. The three above mentioned parts (gaskets, valve and filter), can anyone recommend other businesses other than Ford for getting these parts?
3. I read a mention of replacing head bolts, that factory head bolts allow the head to come away from the gasket/engine block...anyone confirm or deny this, and if it is a problem, recommend a supplier of head bolts?
4. What would cause the EGR valve / EGR filter to be defective?
5. How do you tell if the head gasket is actually blown....if I simply replace the EGR valve / EGR Filter, if I do find the head leaking, can I fix that at a future point in time, or will I have to replace the EGR Valve / EGR Filter again?
5. Is there a Shop Manual of any value that would assist me in this project?
6. Is it just me, or is the 6.0 motor a piece of crap?

I have rebuilt old tractor engines, that sort of thing...is this project to involved for a backyard / farmer mechanic?

Ford estimates over $5000.00 for the repair, $3000.00 of which is labor. The truck has over 200,000 kms on it, so I don't really want to put too much money into it, so if I can fix it myself....

Thanks for any help you guys can give me.

Glenn

 

Welcome to FTE Glenn,I will answer the best I can and others will surely add in.
1. Yes I did the gaskets and got rid of the cooler myself,no it isn't easy.
2. Ford makes good gaskets,the egr cooler and filter I don't know of an aftermarket for them
3. Put studs in..TTY stock bolts suck.
4. The blown head gaskets very likely did it but there are other causes.
5. Yes is on this site (someone want to link it)
6.No it is plagued with the same problems you have now and there are fixes for those problems but a dealer is unlikely to do the deed for you unless your a lucky guy.

 

2004 F-Super Duty 250-550/Excursion Workshop Manual

 

From the factory it is.

But if you're going to add the head studs, that solves its biggest problem.

As far as the EGR is concerned, delete it and the EGR cooler and you've eliminated another big problem.

EGRs on the 6.0 have been known to get clogged up with soot and the coolers have been known to get clogged up with debris from block casting.

Mike

 

to do head gasket job you would most likely to have to pull the motor.as for the egr and cooler it isnt easy but you could probably do it.good luck

 

Hi!

Check out this thread:

https://www.ford-trucks.com/forums/7...headstuds.html

 

https://www.ford-trucks.com/forums/search.php

what's an egr filter? I wouldn't go back to that dealer...