EGR Cooler Replacement Ford 2003-2004 6.0L Power Stroke w/Round Tube (up to 09/22/2003) BD Diesel

Replace a failure-prone cooler

Factory 6.0L EGR cooler cores are known to fail at weak brazed joints, letting coolant into the cylinders, where it can hydrolock the engine and do severe damage.

BD's replacement uses TIG-welded 304L stainless tubes (0.375 in OD, 0.048 in wall), with water deflectors that stir the coolant flow to help shed heat. Each exchange unit is pressure tested and comes with the O-ring and threaded insert. No tuner is needed, and it won't set a check-engine light.

Who it's for

Owners of early 2003-2004 6.0L Power Stroke trucks replacing a failed or failing EGR cooler.

Key specs (per BD)

What's included

• EGR cooler
• O-ring
• Threaded insert

Fitment notes

• Fits 2003-2004 Ford F-250/F-350 Super Duty with the 6.0L Power Stroke and round-tube cooler, built through 09/22/2003. Check your build date with us.
• California: BD says no EO is needed; by design this part is legal in all 50 states.
• Exchange part: ask us about the core.

Professional install available at Powertech Diesel, Idaho Falls — call 208-542-7793.