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Old Apr 14, 2009 | 07:56 PM
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EGR Cooler

What's the word on bypassing EGR Cooler, I know guys who are having this done, they own 03 and 04 F-350 and F-250. I have a 2003 F-350, what are the advantages/disadvantages of having this done.
 
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Old Apr 29, 2009 | 04:41 PM
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In reference to this: I have an 04 F350 6.0 with 70k miles and I just experienced my first EGR cooler failure. On a trip towing approx. 2000lbs. on a bumper car-hauler, white smoke started billowing out of the tailpipe. Pulled over, wrecker hauled to dealership out of town. Of course the warranty is 100k or 5 yrs. and I am 4 months past so it isn't covered. It is going to cost me $3300 for EGR Cooler and Oil Cooler replacement. What's the deal? If this is a prevalent problem, why doesn't Ford have a recall on this problem?
 
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Old Apr 29, 2009 | 05:56 PM
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I have three friends who have 2003/2004 F-350/F-250 trucks all have had EGR Problems. We have all bypassed the EGR cooler.
 
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Old Apr 29, 2009 | 06:05 PM
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But doesn't that make it to where Ford will never work on it again? There needs to be a recall for this problem. I have seen threads where this has happened multiple times.
 
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Old Apr 29, 2009 | 08:46 PM
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I just had my EGR cooler replaced on my 05 F-350 with 63,000 miles.The service manager told me that they replace two to three a week.Definately a problem.I plan on bypassing mine.
 
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Old Apr 29, 2009 | 09:21 PM
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International did have a campaign to install coolant filters on their VT365 versions of the 6.0 built before 1-10-2006. They also advice us to not tolerate any cooling system leaks and to use a vac and fill tool when refilling the coolant system to eliminate the possibility of air pockets.
The problem isn't so much the EGR cooler itself its the fact that the cooling system is plumbed in series and if there are any coolant flow problems such as a plugged oil cooler, the EGR cooler can crack. They corrected this "Achilles heal" when they went to the 6.4 by plumbing the cooling system in parallel.
 
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Old Apr 30, 2009 | 11:05 AM
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Great! With the new 6.4, but that doesn't help me. Ford should recall and fix whatever the problem is, whether it be to install a coolant filter(where do you get this?) or bypass or come out with a good maintenance fix so I can avoid this happening again. Does this type of thing make it now viable to have an extended warranty or some kind of maintenance insurance like US Fidelis?
 
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