ER-0134 2003-2007 6.0L Ford Powerstroke EGR Basic Cooler Kit

2003-2007 6.0L Powerstroke EGR Delete kit

Improve the performance of your motor!

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How it Installation?

Installation instructions

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Step 1 :

1.Disconnect Batteries,Drain coolant,
2.Remove clips for plastic wire way located above turbo. Fold to windshield of truck.

Step 2 :

While holding the manifold up with a small pry bar move the cooler toward the back of the engine. Continuing to hold the manifold up, lift and removethe cooler through the front of the engine. Be surethat all gaskets and o-rings are removed with thecooler.

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Step 3 :

1.Replace intake manifold bolts and torque to 120inlbs.
2.Install the 3/4” silicone hose, 3/4” 180 degree Stainless steel coolant tube provided, and the worm drive hose clamp rings loose on the hose.

Step 4 :

1.Grease the billet adapter o-ring. Place into intake manifold bore. Finger tighten the two longer factory cooler mounting bolts. The third smaller bolt can be discarded.
2.Tighten billet adapter bolts to 120inlbs, while tightening make sure the o-ring stays in place and alignment is correct. Be sure not to over torque the bolts. Slide hose over the oil cooler nipple and tighten both hose clamps.

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Step 5 :

1.Remove factory EGR Valve from intake manifold and install billet block off plate. Torque bolts to 120inlbs. Note: If vehicle throws a code or check engine light consider leaving factory EGR valve in place or install a tuner with egr delete code. 2.Install 2” up-pipe using provided hardware and OEM gasket provided.

Step 6 :

1.Install the bracket. The M10 bolt will be screwed into the support bolt. Secure the transmission dipstick to the bracket using 1/4-20 bolts, nuts, and washers.
2.The bracket will hold the coolant hose connector in place.

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TruckTok 2003-2007 6.0L Ford F250 F350 Powerstroke Diesel EGR Basic Cooler Kit

TruckTok 2003-2007 6.0L Ford F250 F350 Powerstroke Diesel EGR Basic Cooler Kit

$79.99

FITMENT

2003-2007 6.0L Ford F250 F350 F450 F550 Super Duty Turbo (except 2004 F250 Super Duty).
2003-2005 6.0L Ford Excursion Turbo.
2005 Ford F250 Super Duty Lariat Crew Cab Pickup 4 Door.
2004-2010 6.0L Ford E250 E350 E450 Super Duty Turbo.
2004-2005 6.0L Ford E350 Club Wagon Turbo.

DESCRIPTION

Product Overview

If you own a 03-07 Ford 6.0L Diesel, you already know the factory EGR cooler is a major disaster waiting to happen. Prone to carbon clogging and internal cracks, a failing EGR cooler leaks coolant straight into your cylinders, causing blown head gaskets, hydraulic lock, and catastrophic engine failures.
The Heavy-Duty EGR Delete Kit completely bypasses the fragile factory cooler, permanently eliminating the risk of coolant leaks while delivering cleaner intake air, lower engine temps, and restored reliability to your Ford Super Duty truck.

Key Features

High-Strength Upgraded Piping: Replaces the thin, failure-prone factory connection lines with premium 304 Stainless Steel tubes that withstand extreme thermal expansion.
100% Leak-Proof Port Sealing: Utilizes precision-cut, heavy-duty steel block-off plates to completely seal off the exhaust port, preventing hot gas from recirculating.
Prevent Catastrophic Engine Failure: Stops internal coolant-to-exhaust cross-leakage at the ports, 100% eliminating the root cause of blown head gaskets.
Marine-Grade Silicone Couplers: Includes high-temperature, reinforced silicone sleeves that clamp down tightly onto the cooling/intake ports, ensuring zero boost or coolant leaks.

FAQ

Q: Will this setup cause a Check Engine Light (CEL)?

A: Yes, a tuner is recommended. Because this kit physically blocks the exhaust gas flow at the flange port, the engine ECU will detect the change. You will need a custom tune (like Minimaxx Tuner) to turn off the EGR light.

Q: Why should I buy this Y-Pipe along with my EGR Delete/Cooler Kit?

A: To save hundreds in labor costs. To install an EGR kit, you already have to remove the turbo and look directly at the factory up-pipe. Since the factory up-pipes are guaranteed to crack and leak over time, changing it now takes only minutes, whereas changing it later requires another 4-6 hours of tearing down the engine top-end.

Q: How are the open ports handled after removing the factory lines?

A: 100% mechanically sealed. The steel block-off plate bolts directly to the exhaust flange to stop hot gas, while the heavy-duty silicone coupler and T-bolt clamps lock down onto the remaining ports to guarantee zero coolant or pressure leaks.

Q: Will there be any boost or coolant leaks at the block-off points?

A: Absolutely not. We include premium high-temperature silicone connectors and heavy-duty clamps/O-rings. These marine-grade seals are built to withstand extreme pressure and heat, ensuring the modified ports remain 100% leak-free for life.

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