2nd EGR cooler/need help
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Freshman User
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2nd EGR cooler/need help
I have a 2004 f-250 6.0 with 138,000 miles, been in the shop for a bunch of crap, (i.e. 2- egr coolers, high pressure oil pump, ficm) truck has been good but this cooler issue is bullsh*&. was reading the EGR forum about unpluging the EGR wires, if the cooler is leaking(as it is out again) will unplugging the egr wire(where the egr valve is in the closed position)allow the coolant to continue to flow thru it, or do i have to get another cooler put on and then unplug the damn thing?????? please someone help....
Junior User
Joined: Sep 2011
Posts: 54
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From: Central MI
First the EGR cooler. If it's shot, replacing it is the only option. However, there are aftermarket coolers that won't blow again. I think there's another brand out there, I just installed mine from bulletproof diesel. You can also install a delete kit if that is your preference.
Now #2...do you have gauges? You could be in the very shoes I was in a couple months ago. 150k on my '03, pulling a 26' trailer I saw my oil temp up beyond normal and found my degas bottle empty (spewed out the pressure cap). In my case, my oil cooler had expired which as I've read very typically takes out the EGR cooler with it. Again, options. Origianl OEM cooler vs. bulletproof is $2k. I'm betting on the OEM lasting a bit, especially as this was my 1st replacement.
Well there ya have it...90% of my knowledge on the topic
. I'm just a rookie here and a diy'er but I've done all but the warranty work on this truck since '04.
Now #2...do you have gauges? You could be in the very shoes I was in a couple months ago. 150k on my '03, pulling a 26' trailer I saw my oil temp up beyond normal and found my degas bottle empty (spewed out the pressure cap). In my case, my oil cooler had expired which as I've read very typically takes out the EGR cooler with it. Again, options. Origianl OEM cooler vs. bulletproof is $2k. I'm betting on the OEM lasting a bit, especially as this was my 1st replacement.
Well there ya have it...90% of my knowledge on the topic
. I'm just a rookie here and a diy'er but I've done all but the warranty work on this truck since '04.
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Freshman User
Joined: Oct 2011
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Thanks
Thanks Rocket is the one you bought from bullitproof diesel hard to put on I am an also a DIY'er, ford house wants 900.00 for labor, should i get a book? and if so which one is best???also I have never replaced the oil cooler because it has never been bad that i know of should i also change that as well...????
Hotshot
Joined: Apr 2010
Posts: 19,061
Likes: 238
From: Saratoga Springs,UT
Thanks Rocket is the one you bought from bullitproof diesel hard to put on I am an also a DIY'er, ford house wants 900.00 for labor, should i get a book? and if so which one is best???also I have never replaced the oil cooler because it has never been bad that i know of should i also change that as well...????
YES Replace the oil cooler thats why it keeps breaking EGR coolers
like Rocket said get some gauges watch that oil cooler like a hawk
to do these repairs you need to get down to and including the intake manafold out
If your handy it can be done in your driveway with basic hand tools I will post some stuff that helped me ALOT hang on
Hotshot
Joined: Apr 2010
Posts: 19,061
Likes: 238
From: Saratoga Springs,UT
study these
https://www.ford-trucks.com/ford-man...%20Removal.pdf
and this
https://www.ford-trucks.com/ford-man...%20removal.pdf
I will keep diggen for more info but this stuff should be a good start
https://www.ford-trucks.com/ford-man...%20Removal.pdf
and this
https://www.ford-trucks.com/ford-man...%20removal.pdf
I will keep diggen for more info but this stuff should be a good start
Post Fiend
Joined: Oct 2009
Posts: 12,123
Likes: 35
From: N. Fort Worth, tx
please see tsb 09 08 03 info can be found by using the search function
Senior User
Joined: May 2007
Posts: 204
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From: U.P of Michigan
Some great videos from srmastertech on removal, replace and reinstall.
[youtube]fHyEo3wZ9uA[/youtube]
[youtube]psAYkiuapgw[/youtube]
[youtube]d25PPu7PRpU[/youtube]
[youtube]fHyEo3wZ9uA[/youtube]
[youtube]psAYkiuapgw[/youtube]
[youtube]d25PPu7PRpU[/youtube]
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Junior User
Joined: Sep 2011
Posts: 54
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From: Central MI
Thanks Rocket is the one you bought from bullitproof diesel hard to put on I am an also a DIY'er, ford house wants 900.00 for labor, should i get a book? and if so which one is best???also I have never replaced the oil cooler because it has never been bad that i know of should i also change that as well...????
If nothing else it's a good quick education on the issues. Take some of the claims with a grain of salt, they are trying to sell you their stuff. But most of what you see is accurate.
Here was my viewpoint...I've been through some life changing expenditures this year and I'm in debt past my eyeballs. I could either go farther in debt and give a dealer a grand or do it myself. So I cut it down the middle, investing 250 on a topside creeper, about 100 on specialty tools and things to make life easier. These will be mine forever and the job is done.
As for books, etc. I subscribe to alldatadiy, same info as factory service manual for all my vehicles. If you want to minimize investment, I think you'll find just about enough on this site to go on. Be sure to check out Blade's links for a start.
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Thread Starter
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Freshman User
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Thanks guys for the info,I am no diesel mech, but have worked on motors my whole life, so tell me how is the oil cooler bad if it is not leaking? cant you take the cooler off and clean it,every oil cooler that i have seen bad, breaks and leaks oil, so are you telling me that the oil is (not circulating or very little through the cooler)and causing pressure in the egr cooler???
One other question, I have come to the point where i am going to buy the egr delete kit and get rid of this piece of ****, but was wondering is there any way to re-route the coolant lines from the egr cooler and leave the old POS in there for a dummy egr cooler, would you explain how the coolant gets from the egr cooler into the exaust???
and if i keep driving it like it is will i screw up the head gaskets??/ Thanks guys, sorry to ask all of the questions..... so when i put the egr delete kit on am i also taking off the oil cooler in the process(is it part of the egr cooler)?
One other question, I have come to the point where i am going to buy the egr delete kit and get rid of this piece of ****, but was wondering is there any way to re-route the coolant lines from the egr cooler and leave the old POS in there for a dummy egr cooler, would you explain how the coolant gets from the egr cooler into the exaust???
and if i keep driving it like it is will i screw up the head gaskets??/ Thanks guys, sorry to ask all of the questions..... so when i put the egr delete kit on am i also taking off the oil cooler in the process(is it part of the egr cooler)?
FTE Leadership Emeritus
Joined: Aug 2007
Posts: 42,085
Likes: 6
From: Lakewood, Ca.
If the coolant side is plugged up
No, once it's plugged it's trash.
What happens is that the coolant flow is restricted by the clogged oil cooler and can't make it downstream to the egr cooler, which in turn gets too hot and fails at the solder joints.
That is essentially what an egr bypass kit does.
Through the intake manifold when the egr valve opens.
It's possible that the head bolts could stretch and cause the gaskets to fail.
The oil cooler is separate from the egr cooler.
No, once it's plugged it's trash.
The oil cooler is separate from the egr cooler.
Last edited by SteveBricks; Oct 1, 2011 at 07:33 PM.
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Thanks again guys Great video Master tech, man that looks like a lot of work tooo many parts,,lol
so if the coolant enteres the intake, and then you unhook your egr valve, wouldnt that keep the water out of the exaust???? if the egr valve does not open???but then where does it go??? does it fill up the intake manifold?? just have to ask??? man im apretty good mech but this is my first time with a diesel, when i do purchase the egr delete kit and oil cooler upgrade with the remote oil filters this should be bullet proof (at least from this problem anyway) or am i hoping for something that im not gonna find....
If i make it past this endevor i can probably change anything on this truck
Thanks for all the hints and help the video will be priceless..
so if the coolant enteres the intake, and then you unhook your egr valve, wouldnt that keep the water out of the exaust???? if the egr valve does not open???but then where does it go??? does it fill up the intake manifold?? just have to ask??? man im apretty good mech but this is my first time with a diesel, when i do purchase the egr delete kit and oil cooler upgrade with the remote oil filters this should be bullet proof (at least from this problem anyway) or am i hoping for something that im not gonna find....
If i make it past this endevor i can probably change anything on this truck Thanks for all the hints and help the video will be priceless..
Post Fiend
Joined: Oct 2009
Posts: 12,123
Likes: 35
From: N. Fort Worth, tx
I could not see a point to paying $1700 for the bulletproff oil cooler. sure it nice but an oem cooler is $300 even less on ebay.
If I was not doing my own labor and had to pay I may invest in it. but my truck my labor is basicly free. so no big deal for me to spend a few hours rebuilding an oil cooler and saving $1400.
their egr coolers are well built and money more then likly well spent.
the water will bypass the valve as water will leak past it, as water will in almost any situation.
count on a whole weekend adventure to do the repairs. after you have done it a few 100 times it takes less then a half day.
If I was not doing my own labor and had to pay I may invest in it. but my truck my labor is basicly free. so no big deal for me to spend a few hours rebuilding an oil cooler and saving $1400.
their egr coolers are well built and money more then likly well spent.
the water will bypass the valve as water will leak past it, as water will in almost any situation.
count on a whole weekend adventure to do the repairs. after you have done it a few 100 times it takes less then a half day.
MMNC (SS)(Ret)
Joined: Mar 2004
Posts: 11,606
Likes: 149
From: SE Georgia
@cheezit
how often have you had the same truck come back relatively soon with a clogged up oil cooler again?
I know you are supposed to flush the bejesus out of these motors right before changing the cooler...but do they ever reclog immediately?
how often have you had the same truck come back relatively soon with a clogged up oil cooler again?
I know you are supposed to flush the bejesus out of these motors right before changing the cooler...but do they ever reclog immediately?
Post Fiend
Joined: Oct 2009
Posts: 12,123
Likes: 35
From: N. Fort Worth, tx
seen a few. not many though
Lead Driver
Joined: Mar 2010
Posts: 5,505
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From: Woodbridge, Ontario, CA
I have only ever seen ONE truck that needed to have both coolers replaced twice, but it was an E-Series that the owners were very guilty of using for very short distance drives and frequent engine shutdowns or extended engine idling, resulting in a VERY badly carbon clogged up second EGR cooler.