I am in Chicago, kind of far away. I may be able to drop it from the plane as we fly to Alaska for new years, j/k. I wasn't sure if you had some "kits" fabbed up yet. I need to pull the egr and see what is going on in there. I am just about to hit 60k for miles and this is the first sign of trouble I have had.

 

I really don't have a kit, what I do is clean the inside of the cooler and modified it. Then I make some 1/4" Stainless steel plates that goes into inlet and outlet. When I TIG weld the plates, it completely seals the cooler. So the exhaust gas cannot go into the cooler. Also if the cooler leaks, the coolant cannot go into the intake. But if the cooler is good, you wouldn't have to worry about leaks. I do it as a precautionary measure.

With the up pipe, I would TIG weld a 1/4" Stainless steel plate into the place where the up pipe connects to the cooler. Since yours is a 2004, there is no scoop. If there is I would cut it out and remove the scoop. This will keep the exhaust gases from leaking from the flange. There are 3 plug welds that are done, 1 on the up pipe, and 2 on the cooler.

If you worried about the smog police looking at the EGR system. There's no way they can find out without dismantling the EGR system. Which they will not do. It looks completely factory on the outside. On my set up, my 2005 doesn't throw any codes. From what I understand yours won't either.

It took me about 3 hours to complete, if you're interested, sent me an email.
pipewelder71@msn.com

 

Sounds like a Great business to jump into,,,now if you can just find a few EGR coolers to Tig weld up,so you have some on hand,,you could do a core exchange program,,selling the re-vamped EGR's, for whatever time and material, you figure it's worth $$,,,Getting the Core exchange to keep your stock up,,,,and helping out your SuperDuty Brother's !,,,

 

I will have to get under the hood and check some stuff out. Thanks for the info and I will hit you up if I have any more questions/problems. No emission test for Diesel in IL, yet.

 

Pipe Welder I and im sure ALOT of other people would love a step-by-step how to on this! My ford is going to be out of warranty in the next couple months, and this is probably one of the first few things im going to do.

 

lol, @ Darsey-^
i was going to say this one also, Adam is a good guy, he is on several diesel forums as well.

 

I would love to keep some stock on hand. But the EGR coolers are different from 2003-2004 and 2005-2007. I went to the dealership and can see the difference. Even the up pipe is different. I can modify their EGR cooler and up pipe just as easily. Plus you'll know that it will look factory. Most EGR coolers are sent back to the factory as I was told by my tech. A new EGR cooler is about $500.

I still can't believe that they're asking over $500 for the delete kit. My tech told me that $200 to modified the EGR cooler and up pipe is a fair price. So I'll just do that. I figured that it would cover my cost of time, power, welding supplies, materials, and cover the cost of the welder. Then see how it goes.

For those who are not sure about my welding, just to let you know about my background. I'm a UA Union Steamfitter/pipe welder with welding certs. Like an idiot I forgot to take pictures of my set up to show what's done.

I've read before that by doing the EGR delete, emission test actually read lower pollution levels. That's shows the EPA equipment is a joke on diesels.

 

I'll give you the LAT/LONG of my place. That way you can find it. Just let me know, so I can go into another city in case you miss.

 

I though about doing it, but I didn't like the fact that the cooler is still open to the intake manifold. By doing what I'm doing, it removes that possibly of leaking coolant entering into the engine.

My problem is I overbuild everything. So if a part needs 1/8" material, I'll make it out of 1/4" material.

I hate equipment failures.

 

Ive got a cooler for sale in the classifieds for 05-07 for $50 if anyone wants one to "play" with.

 

Is $200 too much?

 

I've read before that by doing the EGR delete, emission test actually read lower pollution levels. That's shows the EPA equipment is a joke on diesels.[/quote]

I will have to agree! I get mine smog checked every 2 years. When the tech came out to hand me the certificate, I asked how did it do? His comment was:this truck is the cleanest emissions that he has tested! What I failed to tell him that I replaced the up-pipe with the blocker plate and HOLLOWED out the CAT.

 

This is what I used eBay Motors: 03-07 6.0 POWERSTROKE FORD EGR COOLER BLOCK OFF KIT (item 360110771620 end time Dec-05-08 03:26:40 PST)

It is basically a 35mm freeze Plug, and double gaskets on the other end with a fabed steel gasket sandwiched between.. It worked great its been on there for about a year now..

 

[quote=TreeTech;6846721]This is what I used eBay Motors: 03-07 6.0 POWERSTROKE FORD EGR COOLER BLOCK OFF KIT (item 360110771620 end time Dec-05-08 03:26:40 PST)

It is basically a 35mm freeze Plug, and double gaskets on the other end with a fabed steel gasket sandwiched between.. It worked great its been on there for about a year now..[/quote

I looked at the same set up, but I wanted something more heavy duty. The kit looks "ok". But if you have a 2005-2007, the up pipe scoop will still be in place if you decided to plug it.

Is your freeze plug stainless steel? If it's carbon steel, over time, it will rust and eat away the stainless up pipe. Did you weld it in place?

 

pipewelder, Thats true as you siad if you have a 05-06 mine is a 04, you will have to deal with the scoop issue. The freeze plug is not stainless, just the standard kind used in every automotive engine today.. You press it in with a hammer and socket/and use (Motorcraft stud/bearing mount)no need to weld... Its highly unlikely that these trucks will still be on the road by the time that freeze plug has a chance to corrode..Plus there is no moisture around it..

The liberator kit is a BIG waste of money people are crazy to pay that! This kit does the same thing for a lot less..