Replace the failed EGR Coolers & Components in your 2003-2007 Ford 6.0L Powerstroke. Common signs that your EGR Cooler could be failing are white smoke, low coolant levels, a sticky EGR valve, or possibly a check engine light. Since the EGR cooler connects the exhaust and cooling systems of your engine, failures inside the cooler can lead to coolant loss, overheating, and possibly engine damage. The first sign of failure is usually white exhaust smoke. This is actually steam from boiling water or coolant. If the EGR cooler has cracked or failed, the coolant passages inside the cooler can begin to leak. The coolant will start to mix with the exhaust and begins to enter the intake. It is then heated either directly by the exhaust, or inside the combustion chamber before being pushed out the tailpipe. As with any coolant leak, you may start noticing a lack of coolant in your overflow bottle. If you have to repeatedly top off your coolant system, and you don't notice any drips or spots on the ground, the coolant may be exiting through the exhaust. Another item to check is the truck's EGR valve. It will typically be black from carbon buildup. If the coolant is entering the EGR system, it can mix with this carbon. Small amounts of coolant can mix with this carbon and will create a sticky buildup. In some cases, there may be enough coolant passing through to strip away the carbon. This leaves the valve looking like it has been steam cleaned. The EGR cooler is designed to lower the temperature of exhaust gases that are recirculated back into the engine. A portion of exhaust flows from the exhaust through the EGR Cooler, where it is cooled before being circulated back into the engine. EGR coolers are a known weak point on many diesel engines and are prone to leaks or blockages. OE-style stock replacements and upgraded EGR cooler designs are offered for many Duramax, Cummins, and Powerstroke applications. Shop all the leading manufacturers such as Bostech, Bullet Proof Diesel, Grizzly Air, Dorman, Alliant Power, Diamond Advantage By Navistar, PPE, AFE Power, XDP, and more!
