I'm looking for a good egr delete for my early 04 6.0

 

IPR gen 2... enough said.

 

I have the Sinister Diesel EGR delete kit and have had no problems. That being said, if I knew then what I knew now I would definitely get the IPR gen 2 kit. I'm actually considering replacing my Sinister EGR delete with the IPR kit.

 

What makes the IPR more appealing?

 

Pretty much all the other EGR deletes mimic the EGR cooler in terms of routing. There's a milled aluminum piece that bolts to the intake, and then a pipe that comes out, heads towards the back of the engine, then curves back towards the outlet from the oil cooler. There is a short hose that connects this pipe with the oil cooler outlet which is held by clamps. The IPR delete eliminates the pipe and uses one piece of milled aluminum to replace the top cap of the oil cooler outlet for a direct connection to the intake. Only two o-rings vs two o-rings and two hose clamps as possible leak points.

 

No hose (as mentioned above), cleaner looking install with less crap in the valley, and better material than the tubing used on some cheap J-tube deletes.

Two notes: the IPR replacement HPOP reservoir screen looks nice, I would get one if doing an oil cooler R&R. Second, I would NOT get the up-pipe from IPR (or get it and sell it), and would go with a different up-pipe setup; the long-term inevitability is you'll either need to get the original y-pipe bellows replaced or get a solid pipe solution.

I'm trying to get a core to get my bellows replaced in the stock y-pipe since I already have the IPR solid up-pipe.

 

Can I weld up my stock egr cooler or is that a bad ideal

 

Works fine if you use thick enough stainless steel slug for the exhaust side plug. Seems like 3/16 gets floated around for what people weld in. You can use a brass freeze plug for the intake side since the exhaust gas is blocked at the back end.

 

what is wrong with the IPR up-pipe?

 

Nothing wrong with the pipe itself, it's probably the best solid up-pipe only I've seen. The problem is using it with the stock the y-pipe. Removing the extra support of the EGR cooler inlet has seemed to cause an increase in the number of bellows on the y-pipe that crack and leak.

You'll end up either replacing the bellows on the stock y-pipe, or going with an aftermarket solution. Instead of getting the IPR solid pipe, you could go straight to one of the other options during the first install so you aren't going in a second time within a year or two.

BD 6.0L Turbo Feed Up-Pipes - Riffraff Diesel Performance
Sinister Diesel Y-Pipes for Ford 6.0L (Raw)
Ford 6.0L Long Y Pipe

 

The IPR Gen 2 is the best but whats said here about the y-pipe cracking is true. Ed over at FICMrepair says it will (not maybe) crack somewhere around 15k miles. you can bet on it.
I'm not looking forward to that repair but pretty sure its coming.
From my research, the best all around solution is welding a puck in the EGR cooler. Keeps everything as it was and will also fool the inspections should there be any.
Here is a pretty good vid on just this issue....

 

I've got 22k miles on my EGR delete with solid up-pipe, no bellows cracks so far.

 

Thanks for the post. That's encouraging. Let us know if you get to 30k with no issues or when you do have issues.

I would have gone the welded plug route but at the time, the dealer i bought the truck from was willing replace the oil cooler for only cost of the parts. I got in touch with their tech and he agreed to also do the delete, dummy plugs, stand pipes, stc as long as i supplied the extra parts so i had to go with the delete.
He was a seasoned diesel tech direct from Ford and knew his stuff. I got very lucky. so i figured it was worth it to have to do the y-pipe whenever it decided to go. I did get all the old parts from him including the egr cooler in case i ever wanted to plug it and reinstall.

 

You wont go wrong with this up pipe kit....

Up Pipes | 03-07 Ford Powerstroke 6.0L | Thoroughbred Diesel


I did the EGR delete and oil cooler, went 20k miles and had to do an HPOP...2 weeks later I installed up pipes. Do the up pipes when you do the delete.

 

Thanks for the link. How hard to do the up pipes install?