I have my truck in the shop. Since I'm having my head studs installed , I figured that I'll do something with the EGR cooler.

I looked at the Liberator EGR delete kit I about fell through the floor, $595. That's just way too much money for a simple kit. So I'm thinking about taking my EGR cooler and up-pipe to my shop.

I figured that I can take out the scoop in the up-pipe. Then just inside the flange, I'll weld in a stainless steel plate to seal it from the exhaust gases. That will be done.

Then I will take the cooler and clean it up. I can fabricate some blocking plates on inlet and outlet side for the exhaust gases in the cooler to seal it.

This way the coolant can continue to flow through. If the cooler does fail, with the ends sealed up, I don't have to worried about it leaking. Also if a shop doing work sees it still installed, then I don't have to worry about them asking questions. Then install it, no quess work.

I seen a new EGR cooler ($488) at a Ford dealership. Just to see what I can do and get away with. It should work. I can fab up something like the Liberator EGR delete kit, but I need time to fit it up and weld it.

Do you think this will work? Any other suggestions? The cab's lifted, but they haven't cracked open the engine yet, will start on Monday.

Thanks

 

good ideas. Also look into First Coast Diesel Performance

 

egr stuff really confuses me. there are a couple good threads going on about deletes and modifications with pictures and write up. i like the look of the first coast one aswell.

 

When I looked at a new EGR cooler from Ford. The body of the cooler is pretty heavy duty. Plus it's Stainless Steel material, it can handle alot of pressure and heat.

The cooler is just like a heat exchanger, I wonder if you could cut one end open and try to remove the guts of the cooler. Then weld it up, that way, there's no soot in your coolant if it leaks.

I really should look into a coolant filter. I'm not working right now because of injuries, so my funds are really limited.

I should get my cooler and up-pipe Monday, then I'll modified it. I guess I should take some pictures for the forums.

 

I think your plan will work great. Furthermore, the lack of exhaust gas going through the cooler should drasticly reduce the chances of a leak in the first place. I have been thinking of doing something like this. I worry about the fact that the EGR valve would be missing, what about making the bottom of the valve the top block plate? Cut the valve off and run the bolts through the valve and then the block plate. You could even plug in in. Just a thought.

 

The scoop is the only thing that I would worry about. Can it be removed without cracking the flex part?

 

By blocking the up-pipe and also the inlet of the cooler, there's no way that the exhaust will enter the EGR cooler. Also the heat transfer of blocker plate will be very low because of the blocking of the pipe and cooler.

I would think that it doesn't matter if the valve functions or not, because the outlet of cooler will also be blocked off. I believe that the EGR valve is in the intake manifold, which I'm not going to modify. There's really no need to.

 

A sawzall with a long blade can easily reach it. Then you can take an end grinder with a flapper wheeler and smooth it out. The flex joint is on the other end. So it's pretty simple.

 

I just remember that the 2003-2004 up-pipe and EGR cooler is actually different than the 2005-2007. I forgot to mention that in case if anyone is looking into this.

It's pretty easy to get mixed up if you not familiar with the parts. But nevertheless, you can do this set up with 2003-2004 as well.

I think this would be the easiest and cheapest way to ensure that you'll never have problems with the EGR cooler again.

 

I understand the the EGR system would not work. I was wanting it to appear like it was working.

 

you might want to look into the "sneaky pipe"

 

I got my truck back. It's been studded ,the modified EGR cooler and up pipe is working great. I haven't seen any codes thrown out. Also I haven't really had the chance to hammer down too much on it yet (too much rain). The EGT's cooler and the MPG is a little better (on stock tune). You can't tell that the EGR cooler and pipe is modified once it's installed. That's what I wanted.

I just realized yesterday that I didn't take any pictures of the modified EGR cooler. It totally slipped my mind.

But the dealership that did the work, was so impressed with the work on the cooler and the up pipe. They called a few people who have heavily modified Fords to check it out. My tech told me that one of them that spent over $500 on a delete kit, wished that he did the way I did it.

When I came in to pick the truck, I had some people come up to me and wanted to have me modified the EGR cooler and up pipe for future customers. They were saying that soon, there will be alot of 6.0 trucks coming off the warranty. So they wanted to offer another solution to the EGR cooler problems.

I was taken back, but I'm set up for it now. I TIG weld the block plates in, but I did it differently then the ones seen elsewhere. Also, it is stainless steel.

Maybe I'm on to something.

 

Sounds like a business opportunity.

 

So what can you do for my 2004. I recently have started to have problems with big drops in fuel mileage, from 17mpg to 11mpg. I suspect the egr is plugged and have been looking into the egr delete but $500-$600 is crazy. I spent less on my turbo back exhaust.

 

Can you remove the EGR up pipe and EGR cooler? Since I've done mine, I have had ZERO problems and runs cooler. Where are you at?