BD Diesel EGR Cooler Replacement - Ford 2004-2007 6.0L PowerStroke w/Square Tube (after 09/22/2003)

If you're working on a 2004-2007 Ford E-350 Super Duty with the 6.0L Power Stroke engine, specifically those built after September 22, 2003, and featuring the square tube EGR cooler, this replacement unit from BD Diesel is a solid option. The factory EGR cooler's brazed joints are a known weak point, and when they fail, coolant can leak into the cylinders. This can lead to serious engine damage, so replacing it with a more robust unit is a smart move.

BD Diesel builds this EGR cooler with TIG welded 304L stainless steel tubes, measuring 0.375 inches in outer diameter with 0.048-inch walls. This construction is much stronger than the original's brazed design, helping to prevent premature failure. They've also added water deflectors inside the tubes to increase coolant turbulence, which aids in heat dissipation and keeps the coolant flowing efficiently. This unit is pressure tested to ensure it's ready to go right out of the box, and it comes with the necessary O-rings and a threaded insert for installation. Importantly, it's designed to be a direct replacement and won't require any special tuning or cause your check engine light to come on.

This EGR cooler comes with a gasket set and is built to last. It's a well-built component designed to address a common failure point in these specific Ford Power Stroke engines.