Hello, this question has been rolling around in my head for a while and I can't get rid of it. So I thought I would throw it out to see if it will get an answer or get out of my head.

Anyway, since the primary cause of the EGR cooler failure is poor coolant flow from clogged or partially clogged oil coolers, and with all the engineering that has gone into upgraded egr coolers, egr deletes, oil cooler upgrades and programing, why hasn't someone simply developed a kit to re-route the coolant? Provide a dedicated coolant supply for the EGR cooler and route the spent oil cooler coolant back to the degas bottle.

I feel much better now.

 

Someone kinda sorta did, but they've been very quiet about it.

A buddy of mine has something similar to your idea on his 2005 F350. The re route hose T's into the line going to or from the coolant reservoir (don't remember) and actually increases the flow and pressure of the coolant thus keeping things cooler and reducing the likelihood of the oil cooler clogging again if ever.

 

Come on TD.... give it up, all of it.

 

The only question I can think of right now is ....why would a buddy of yours want to keep this from the rest of us in the 6.0 community? I mean even if He/She wanted to put some kind of patent or something so's to benefit themselves monetarily ( which I can't say that I'd blame them)...I would think they would want to give back a little, maybe? (assuming that they have gleaned a little helpful info from the rest of us). If not, maybe you'd be so kind as to tell us who they are and we could it out of 'em

 

interesting.....

 

I got a few tricks up my sleeve, but there not proven yet. i got to make sure they work first!...............kinda like the 6.4 cam,but what do I know?

 

Awesome, can wait to hear the details.......

 

Routing the spent oil cooler coolant to the degas bottle or heater return hose seems easy enough but providing a coolant supply for the egr cooler might be a little harder. Could you "T" or "Y" off from the heater supply prior to the valve or would this restrict the flow to the cooler or to the heater? Or would the water be to hot since it has already been through the engine?

 

Kind of the same theory as the External oil cooler, being out of the hot molting block , and up where the air flows, engine bay is cooler than tucked away in side the 6.0 Volcano

 

You might be onto something there. The coolant coming off the oil cooler is pretty hot, no idea how hot. Seeing as the oil coming out of the cooler is usually 5-10F hotter than the coolant coming out the thermostat, I'd bet the temp out of the Oil cooler is pretty close to engine temp.

Somebody needs to drill a temperature tap in their EGR delete kit, then we could measure it.

Would also need some way of balancing the flow thru the EGR. I'm guessing the oil cooler is a much higher restriction than the EGR so EGR itself might take too much flow. That could be solved with a simple orifice (if we knew all the design flows pressures).

 

You could theoretically route the oil cooler to the heater return and tee off the heater supply for the EGR cooler.

That's a lot to do to keep a somewhat healthy EGR cooler when in reality it would be easier to either monitor the oil cooler health or delete the EGR

Josh


Josh

 

Sorry I didn't reply sooner, been horribly busy at work and working on the truck.

It's not that he kept it from the 6.0 community, the guy who made it for him did. I'm not sure that he ever went public with it. Folks with an EGR cooler would appreciate this as increases flow and pressure (within reason) of the oil cooler increasing it's efficiency.

 

You're right a BPD egr cooler or delete and monitoring temps is a better option now. I guess the Ford and IH engineers and bean counters probably considered a different coolant supply when the egr coolers started rupturing and decided the warranty costs would be less than redesign costs. I don't think that the 6.4 egr cooler is supplied from the oil cooler.

I would think though that companies like IPR, Sinister, BPD, etc. would have at least considered a dedicated coolant supply approach to the issue.

Oh well, go figure.

 

I personally feel the OEM oil cooler works very well, if it's seeing fresh Ford Gold (30k flushes) or ELC.

With a healthy oil cooler I do not believe there is much of an issue with failed OEM EGR coolers. Should Navistar have designed a daisy-chain of the oil cooler into the EGR cooler? No, it's a very poor execution of 2 vital components relying on coolant to function adequately.

With that said, if it's at all possible, I will always recommend deleting the EGR function. Once deleted, the cooling function is no longer a concern. Even the magic 15 degree temp spread is a moot point.

Hindsight being 20-20, the intake manifold should have been designed to allow the oil cooler housing to be removed for servicing easier. The EGR cooler should have been designed with it's own coolant supply independent of the oil cooler.

The 6.0 is well thought out and yet at the same time it's obvious it was kinda just thrown together. The 6.4 is even worse for being thrown together.

Why hasn't someone cobbled up a kit tee'd into the heater supply/return? Not sure, Could be worth a shot and giving it a trial. But will it be more beneficial than say a healthy OEM oil cooler and a stealth delete?

Josh

 

As I recall it was Ford's idea to use a coolant that has silicates and IH recommended that
not use it. But Ford was building the truck on a line that already used gold and they are cheep.

That all being said we know that keeping clean fresh coolant in the system is very effective.
The problem or at least part comes from not changing the coolant when it should be.


Anyway a change in the system really would not be that hard if you have access to a mill
and maybe a lathe to make some parts. The hard part is the testing in the different conditions
and then monitoring the data and proving the effectiveness of the change.




Sean

6.0L Tech Folder