I could use some help. I noticed a fluid leak at the coolant supply hose on the horizontal EGR cooler. Upon visual inspection, the edge of the hose is wet where it connects to the cooler. I dropped by a local Ford dealer and the mechanic took one look and said, "you have a failed EGR cooler, expensive!"

Looks like a loose hose clamp to me with fluid around this connection. Am I missing something here?

I have no white smoke. I noticed a wet spot on the driveway which got me looking for the leak. My resevior was nearly empty but I haven't checked the level in a while.

 

so, did you check the clamp to see if it was tight?

 

Not yet. I'm on vacation and haven't bought a screw-driver.

 

Senix,

I'm 325 miles from home and my trusted mechanic. I'll get a hold of a flat blade this afternoon. I'm more concerned with the local mechanics quick visual observation and whether I can make it home.

I know this hose leak has left residue all over the back pressure sensor and the under body but what am I missing that made the mechanic believe this is a failed cooler? I have no white smoke and the reservoir is holding fluid.

Thanks again, Rob

 

Its hard to say, but a leak at that joint wouldn't necessarily mean anything failed but the seal. I would tighten the clamp and then check for leaks. If there is still a leak it will be easier to localize at that point.

Hopefully this is a simple fix!

 

Any update on this? Just curious how you made out.

 

Since tightening the hose clamp I haven't lost a drop of fluid. I'm taking into Ford tomorrow to have the engine oil operating temp monitored and the cooling system flushed and checked. I'll keep you posted.

 

Was curious. They can pressure test the system and go from there as well.

 

I'm back! My truck is at Ford and BulletProof EGR Coolers are on order shipping next day air.

Ford gave my rig a clean bill of health last year after pressure testing my EGR coolers. A loose hose clamp was the culprit that time around.

This time I noticed a loss of power on Wednesday cutting out at 2500 RPMs. The next morning I drove into work and while parking, the engine light came on and I couldn't go more than 5mph. The engine idled perfectly, just wouldn't go. I had AAA tow her into the dealer yesterday.

The thrown code was pointing my mechanic to a bad EGR valve which they replaced but also found engine coolant beneath. So here I am again, 126K miles and my first pair of EGR coolers.

I considered an Elite Diesel EGR delete kit for a moment. I hope I didn't make a mistake.

 

New style EGR valve deletes the coolant going to it.

 

The Navistar Maxxforce 7 (6.4) does not use 2 EGR coolers any more, there down to 1 cooler. Just wondering if their new setup is compatible with the Ford 6.4 version.

 

I doubt it, as I believe the Maxxforce 7 has always used one EGR cooler from the beginning in 2007. The Super Duty pickups have to pass a completely different set of emissions tests than medium duty trucks that the Maxxforce engine would be in, and I believe this is why the different turbo and EGR system.

 

Are you guys suggesting 'delete kit' or EGR cooler replacement?

I can return the BulletProof coolers and buy the Elite Diesel kit with bypass. I need some direction.

Thanks,
Rob

 

Are you tuned and deleted?

 

No tune or delete. I've been on the fence with buying a Spartan tuner. I'd be interested in increased fuel economy vs race tuning. I haul a camper and boat primarily.