Ford

Ford

  • EGR500-3

    Bostech

    Ford 6.0L EGR and Oil Cooler Package 2004-2010 | 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 Incudes Engine Oil Cooler - EOC02812 Direct Fit, Ready to Install Gasket Kit...
    Sale Price: $399.95
  • EK025001

    Bostech

    Ford 6.0L EGR Cooler and Valve 2004-2010 | EK025001

    Sale Price: $359.90
    Ford 6.0L EGR Cooler and EGR Valve Kit Exceeds OE Performance Manufactured with stainless steel tubing Tig Welded Tubing for Extreme Durability Includes EGR Valve - EGV02600 Direct Fit, Ready to Install Gasket Kit included - EGR02505K Proudly...
    Sale Price: $359.90
  • EGR500

    Bostech

    Ford 6.0L Tube Design EGR Cooler 2004-2010 | EGR500

    Sale Price: $259.95
    Ford 6.0L EGR Cooler Kit - EGR500 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 Free...
    Sale Price: $259.95
  • EGR501

    Bostech

    Ford 6.0L EGR Cooler 2003 | EGR501

    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 Free Shipping +...
    Sale Price: $259.95
  • EGR501-3

    Bostech

    Ford 6.0L EGR and Oil Cooler Package 2003 | 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 Includes Engine Oil Cooler - EOC02812 Direct Fit, Ready to Install Gasket Kit included Proudly...
    Sale Price: $399.95
  • EGR501-4

    Bostech

    Ford 6.0L EGR w/ Oil Cooler & Intake 2003 | 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 Includes Engine Oil Cooler - EOC02812 Includes Intake Manifold - EGR502 Direct Fit, Ready to...
    Sale Price: $699.95
  • EGR500-4

    Bostech

    Ford 6.0L EGR w/ Oil Cooler & Intake 2004-2010 | EGR500-4

    Sale Price: $699.95
    Ford 6.0L EGR Cooler Kit - EGR500-4 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Includes Engine Oil Cooler - EOC02812 Includes Intake Manifold - EGR503 Direct Fit, Ready to...
    Sale Price: $699.95
  • EGR501-5

    Bostech

    Ford 6.0L EGR w/ Oil Cooler, Intake & Valve 2003 | EGR501-5

    Sale Price: $799.95
    Ford 6.0L EGR Cooler Kit - EGR501-5 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Direct Fit, Ready to Install Gasket Kit included   Kit Contains: Engine Oil...
    Sale Price: $799.95
  • EGR500-5

    Bostech

    Ford 6.0L EGR w/ Oil Cooler, Intake & Valve 2004-2010 | EGR500-5

    Sale Price: $799.95
    Ford 6.0L EGR Cooler Kit - EGR500-5 Remanufactured EGR Cooler by Bostech New Stainless Steel Tubing Design Bostech Solutions Cooling Exceeds OE Performance Includes Engine Oil Cooler - EOC02812 Includes Intake Manifold - EGR503 Includes EGR Valve -...
    Sale Price: $799.95
  • E-2565K

    ForDiesels

    New Ford 6.4L EGR Cooler Kit | 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...
    Sale Price: $499.95
  • EGR504

    Bostech

    Ford 4.5L /Navistar VT275 EGR Cooler | 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
  • EGR502

    Bostech

    Ford 6.0L Intake Manifold 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...
    Sale Price: $299.95

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.