EGR Cooler failure
 

My B-I-L calle dthe other evening about his 04. Said it was running rough, steaming out the exhaust, no power. He and I both were thinking headgasket.

Anyhow turns out he had a failure of the EGR Cooler! anyone know anything about this type failure?

Also he was talking to the lead service person and they told him that the 07's and on were a mess to work on. Have to pull the cab to get to the engine for any repairs. Anyone heard this yet?

Thanks

hank

i think pulling the cab is the norm on most of them.

Yes, and Yes; EGR cooler and the cab off...even seen 3 Duramaxes in the shop with the cabs off last year.

Ford modified the hose and or fitting to the EGR cooler many months ago for latter '04's. Dealer had to pull the turbo to get to it but not the cab.

(according to them.)

Cab lifts are done all the time, especially for headgaskets, which is now common.

Was in new dealer's shop two days ago. They had two in with the cabs lifted off.

(so sad!)

Cab removal is not necessary for an EGR cooler. An experienced tech should be able to replace it in just a couple of hours...

My EGR valve went on my 04 late last fall and they had to also replace the cooler gasket. Same symptoms your describing. Lots of white smoke, no power. It was in the shop a couple of days. No problems since. They didn't pull the cab.