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Ford

Ford

  • EGR500

    Bostech

    Bostech EGR Cooler - Ford 6.0L 2004-2010 | EGR500

    Sale Price: $259.95
    Ford 6.0L EGR Cooler and EGR Valve Kit Installation Gaskets Included Direct Fit Technical Information: EGR Cooler: Bostech EGR Cooler with Stainless Steel Tubing Includes Intake and Turbo Installation Kit Ford 6.0L Engine Applications: E-350 Club...
    Sale Price: $259.95
  • EGR500-8

    Bostech

    Bostech EGR Kit - Ford 6.0L 2004-2010 - EGR / Oil Cooler / EGR Valve | EGR500-8

    Sale Price: $498.95
    Ford 6.0L EGR Cooler Kit with Oil Cooler - EGR500-8 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Kit Contains: EGR500 - Bostech 6.0L EGR Cooler GK02505 - Bostech 6.0L Intake...
    Sale Price: $498.95
  • EGR500-3

    Bostech

    Bostech EGR Kit - Ford 6.0L 2004-2010 - EGR / Oil Cooler | EGR500-3

    Sale Price: $399.95
    Ford 6.0L EGR Cooler Kit with Oil Cooler - EGR500-3 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Kit Contains: EGR500 - Bostech 6.0L EGR Cooler GK02505 - Bostech 6.0L Intake...
    Sale Price: $399.95
  • EGR500-6_ANG

    Bostech

    Bostech EGR Kit - Ford 6.0L 2004-2010 - EGR Cooler / EGR Valve | EGR500-6

    Sale Price: $324.95
    Ford 6.0L EGR Cooler with EGR Valve - EGR500-6 Installation Gaskets Included Direct Fit Kit Contains: EGR500 - Bostech 6.0L EGR Cooler GK02505 - Bostech 6.0L Intake & EGR Gasket Kit Includes Ford Motor Company's Original "Blue Hose" EGV02601 -...
    Sale Price: $324.95
  • 904-262

    Dorman Products

    Dorman 904-262 EGR Cooler - Ford 6.0L 2004-2010

    MSRP: $345.95
    Sale Price: $299.95
    New Ford 6.0L EGR Cooler New EGR Cooler Spiral Stainless Tubing Installation Gaskets Included Direct Fit Technical Information: CARB Complaint - YES CARB Executive Order Number - D-740-1 Gaskets Included - YES Material - Stainless View Product...
    MSRP: $345.95
    Sale Price: $299.95
  • EGR501

    Bostech

    Bostech EGR Cooler - Ford 6.0L 2003-2004 | EGR501

    MSRP: $324.04
    Sale Price: $259.95
    Ford 6.0L EGR Cooler Kit - EGR501 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Direct Fit, Ready to Install Gasket Kit included Proudly Manufactured in the USA Lifetime Warranty ...
    MSRP: $324.04
    Sale Price: $259.95
  • EGR501-7

    Bostech

    Bostech EGR Kit - Ford 6.0L 2003-2004 - EGR / Oil Cooler / EGR Valve | EGR501-7

    Sale Price: $498.95
    Ford 6.0L EGR Cooler Kit - EGR501-7 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Direct Fit, Ready to Install Gasket Kit included Proudly Manufactured in the USA Lifetime...
    Sale Price: $498.95
  • EGR501-4

    Bostech

    Bostech EGR Kit - Ford 6.0L 2003-2004 - EGR / Oil Cooler / Intake | EGR501-4

    Sale Price: $699.95
    Ford 6.0L EGR Cooler Kit - EGR501-4 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Direct Fit, Ready to Install Gasket Kit included Proudly Manufactured in the USA Lifetime...
    Sale Price: $699.95
  • EGR501-3

    Bostech

    Bostech EGR Kit - Ford 6.0L 2003-2004 - EGR / Oil Cooler | EGR501-3

    Sale Price: $399.95
    Ford 6.0L EGR Cooler Kit - EGR501-3 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Direct Fit, Ready to Install Gasket Kit included Proudly Manufactured in the USA Lifetime...
    Sale Price: $399.95
  • Bostech EGR Kit - Ford 6.0L 2003-2004 - EGR Cooler / EGR Valve | EGR501-6

    Bostech

    Bostech EGR Kit - Ford 6.0L 2003-2004 - EGR Cooler / EGR Valve | EGR501-6

    Sale Price: $324.95
    Ford 6.0L EGR Cooler Kit - EGR501-6 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Direct Fit, Ready to Install Gasket Kit included Proudly Manufactured in the USA Lifetime...
    Sale Price: $324.95
  • EGR500-4

    Bostech

    Bostech EGR Kit - Ford 6.0L 2004-2010 - EGR / Oil Cooler / Intake | EGR500-4

    Sale Price: $699.95
    Ford 6.0L EGR Cooler Kit with Oil Cooler - EGR500-4 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Kit Contains: EGR500 - Bostech 6.0L EGR Cooler GK02505 - Bostech 6.0L Intake...
    Sale Price: $699.95
  • EGR500-7

    Bostech

    Bostech EGR Kit - Ford 6.0L 2004-2010 - EGR Cooler / Turbo Up Pipe | EGR500-7

    Sale Price: $399.95
    Ford 6.0L EGR Cooler Kit with Oil Cooler - EGR500-7 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Kit Contains: EGR500 - Bostech 6.0L EGR Cooler GK02505 - Bostech 6.0L Intake...
    Sale Price: $399.95
  • E-2565K

    ForDiesels

    ForDiesels EGR Cooler Set - Ford 6.4L 2008-2010 - 2 Coolers | E-2565K

    Sale Price: $499.95
    Ford 6.4L EGR Cooler Kit - E2565K New EGR Cooler Kit by ForDiesels.com Stainless Steel Tubing Design Includes both EGR Coolers Gasket and Hardware Included Ford 6.4L Engine Applications: F-250 Super Duty 2008-2010 F-350 Super Duty 2008-2010...
    Sale Price: $499.95
  • EGR504

    Bostech

    Bostech EGR Cooler - Ford 4.5L /Navistar VT275 | EGR504

    Sale Price: $399.95
    Ford 4.5L EGR Cooler - EGR504 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech EGR Cooling Solutions Exceeds OE Performance Direct Fit Proudly Re-Manufactured in the USA Application: Ford LCF 4.5L V6 Vin Z  2006-2010...
    Sale Price: $399.95
  • EGR464

    Bostech

    Bostech EGR Cooler - Ford 6.4L 2008-2010 - Horizontal | EGR464

    Sale Price: $399.95
    Ford 6.4L EGR Cooler Kit - EGR464 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Direct Fit, Ready to Install Gasket Kit included Proudly Manufactured in the USA Fitment Note: ...
    Sale Price: $399.95
  • EGR456

    Bostech

    Bostech EGR Cooler - Ford 6.4L 2008-2010 - Vertical | EGR456

    Sale Price: $349.95
    Ford 6.4L EGR Cooler Kit - EGR456 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Direct Fit, Ready to Install Gasket Kit included Proudly Manufactured in the USA Fitment...
    Sale Price: $349.95
  • EGR502

    Bostech

    Bostech Intake Manifold - Ford 6.0L 2003 | EGR502

    Sale Price: $299.95
    Ford 6.0L Intake Manifold - EGR502 Remanufactured Intake by Bostech Extensive Cleaning Process Pressure Tested for Leaks Direct Fit Fitment Note: Production Date up to 9/21/2003 Application: Ford Excursion 6.0L V8 Turbo Vin P 2003-2004 F-250 Super...
    Sale Price: $299.95
  • 904-405_ANG

    Dorman Products

    Dorman 904-405 EGR Cooler - Ford 6.7L 2011-2019

    MSRP: $360.20
    Sale Price: $259.95
    Ford 6.7L EGR Cooler Kit - 904-405 Dorman OE Solutions Gasket Kit Included Direct Fit, Ready to Install Technical Information: CARB Compliant - No Material - Stainless Steel Inlet ID - 2.0 inches Outlet ID - 2.0 inches Ford 6.7L Engine...
    MSRP: $360.20
    Sale Price: $259.95
  • On Sale
    E-2556

    ForDiesels

    ForDiesels EGR Cooler - Ford 6.4L 2008-2010 - Vertical| E-2556

    MSRP: $349.95
    Now: $279.95
    Was: $349.95
    Ford 6.4L EGR Cooler Kit - E-2556 New EGR Cooler by ForDiesels New Stainless Steel Tubing Design Direct Fit, Ready to Install Gasket Kit included Fitment Note:  Vertically Mount  Application:  Ford F-250 Super Duty 6.4L V8 Turbo...
    MSRP: $349.95
    Now: $279.95
    Was: $349.95
  • On Sale
    E-2564

    ForDiesels

    ForDiesels EGR Cooler - Ford 6.4L 2008-2010 - Horizontal | E-2564

    MSRP: $399.95
    Now: $299.95
    Was: $399.95
    Ford 6.4L EGR Cooler Kit - E-2564 New EGR Cooler by ForDiesels New Stainless Steel Tubing Design Direct Fit, Ready to Install Gasket Kit included Fitment Note: Horizontally Mount  Application:  Ford F-250 Super Duty 6.4L V8 Turbo Vin...
    MSRP: $399.95
    Now: $299.95
    Was: $399.95

Ford EGR Cooler 6.0

In the effort to improve diesel engine emissions engineers have designed a system for cooling the engine exhaust and directing about 30% of the total volume back into the intake – the ERG cooler. 

This is being done in an effort to reduce the amount of nitrous oxide gas coming out the tailpipe. This all started with the EPA tier one emissions standard. The first Ford Diesel EGR coolers were installed on the 2002 Ford Powerstroke Diesel with the 6.0-liter engine. This engine came with a tube-style round EGR cooler and an electronically controlled EGR valve. Ford continued with this system throughout the life of the 6.0 engine life. They made some changes in the engines produced after 9/2003. The EGR cooler design was changed slightly. The redesigned EGR cooler 6.0 used a turbulator square cooler. This cooler should have cooled the exhaust more efficiently. The Ford Powerstoke 6.4 engine was produced with two EGR coolers starting in 2008. These coolers are failing just like the 6.0. We have many customers that have experienced engine failure due to the engine hydro locking when coolant is introduced into the engines intake manifold.


The Ford EGR cooler designs have been a disaster for Ford Powerstroke Diesel owners. Many trucks have had the cooler replaced multiple times in the first 100,000 miles. 

The Ford Powerstroke EGR cooler 6.0 failure can be attributed to a few things: In addition to the design flaws, coolant going into the cooler goes through the engine oil cooler prior to entering the EGR cooler. The engine oil cooler passageways are very small and become restricted with engine casting sands. The casting sands from when the engine was made. The sand is released over time and gets trapped in the oil cooler, restricting coolant flow into the cooler. This condition causes the EGR cooler 6.0 to run low of coolant. This will cause steam and create extreme heat in the EGR system. 

The Bostech EGR Cooler is designed using much stronger end plates and stainless steel tubes. This design can withstand the many heat cycles from daily use, extreme conditions during hard pulling, or very hot desert conditions. This design minimizes cooler failure due to diesel particulate. 

A few things should be considered when servicing the Ford Powerstroke EGR cooler 6.0: 

The first thing to consider is how to clean the exhaust deposits in the intake system and EGR valve. The intake can be cleaned of deposits with many hours of pressure washing, or you can get a ready to install intake from Bostech. Bostech makes this easy at an economical price. The next would be the EGR valve. Then consider replacing the engine oil cooler. The oil cooler is located under the EGR cooler. The labor to install the oil cooler at this point is minimal.