Well, original owner, 81k well cared for miles! Changed the oil every 2k, same with fuel filter, do the egr clean annually and injector clean same time. EGR went out with 20K on engine, no problems since. Ran fine last weekend, fired up this weekend and smoke EVERYWHERE, no power, turbo making a loud noise, low on coolant 1 1/2 gallons. Soooo, took it to local Ford shop (EXCELLENT guys down here at Butch Oustalet Ford Gulfport in teh service and parts dept!). Anyway, EGR and OIL cooler shot! Talked to them and to my buddy in Louisiana who is the Service Manager also and they say there is a NEW kit, re-engineered now they are using and they do both at the same time and have had no failures with it as of yet! I can only hope for the best, LOVE my F-250, looks like the day it came off the showroom floor. They said they will pressure test the motor and make sure no head gasket issues at same time, etc etc etc. It's paid for, first problem ever. They are working with me on the costs associated.

Has anyone else had this NEW kit with EGR and Oil Cooler put in yet?

 

Sounds like they're blowing more smoke than your truck.

Haven't heard of any "new kit" Only fix is to delete that EGR setup.

Why do you change your oil and fuel filters every 2k miles? That seems quite excessive.

 

Well, I have called three different dealers now and all say it is a newly engineered oil cooler and egr cooler part and with over 300 installed they have not had a single repeat problem. My dealer has gone so far to warrant me the parts and labor FOREVER! On top of that, they said if my head gaskets go or heads they would even do all of that for me at NO COST TO ME! Even if a truck is out of warranty, there are a LOT of things a dealer can do for you from a local company level with dollars! Trust me, they just hooked me up like I never dreamed of! Heard my truck running today and sounded sweeeeet! My local dealership goes above and beyond!

 

There is a company called bullet proof diesel. Ford Power Stroke 6.0L Parts Upgrades from BulletProofDiesel.com
We install their updated coolers at the independent shop I work at, and they are fantastic! They are much better built, and dont seem to have the problems that Fords have had. I worked in a Ford shop for a couple years and EGR/oil coolers seemed to be half of the 6.0 repairs, right along with injectors.

 

also MKM customs makes a kit but it is an egr delete and has something to do with the oil cooler but it also comes with head studs and gaskets and alot of other fun toys. may wanna check into that

 

I know a few people running Bullet Proof EGR Coolers and they are very happy with them. I've seen them in person and I agree they are a very nice piece.

 

Well. truck went in Monday about noon and got it back Tuesday evening! I went into the garage and got a chance to see all that was going on (man what a croweded mess!). Anyway, EGR cooler is the same, what it seems they do now is take apart the oil cooler and put a different internal guts into it? They also said they flush something DCV9 or whatever it is called to clean out the rust or particulates in the coolant system? They said they started doing this about a year ago? I have no idea if my EGR cooler went out or did the oil cooler go out and thus the fluid that comes from the oil filter and goes to the egr cooler stop and ruin that? My buddy in Louisiana has done about 200 of these in the last year and said they had not had a single return. My local dealer has said the same. So, the truck is paid off, 4 1/2" Donahoe racing lift kit, bilsteins, 35" Toyos and nice 20" wheels, custom stereo, external fuel tank, spray in bed liner, tool box and the truck looks like the day I purchased it! Oh, and paid off. Don't want a Dodge or Chevy or Nissan or Toyota so guess I just stick it out and enjoy it as long as it lasts?

 

They probably just did a rebuild of the oil cooler. They get clogged with crap from the coolant system since the block is sand cast. Over time this casting material ends up in the oil cooler causing blockages and this can lead to rising coolant temps and further issues with the EGR cooler. If they didn't fix the headgaskets or replace the EGR cooler, where was your coolant going to and what did they do to fix it? I dont follow this one bit. Where did that 1 1/2 gals of coolant go? The EGR cooler was updated back in 04, all of the newer trucks have the square style cooler, vs. the 03's round tube style. If you look on bulletproofs website you can get either design last I knew.

You may want to invest in a coolant filter kit from www.dieselsite.com This will be my next purchase for my 6.0 I know that.

Post some pics of your truck, it sounds awesome.

 

I guess I said it wrong. They "replaced" the entire EGR cooler (the part I believe is the very same part number). They took apart the oil cooler and put in new internals. They flushed my entire system with VC9, then flushed again, and then put in all new Ford Gold and the additive. Now, what has my at a total loss after doing some reading is "what the heck makes the oil cooler fail in the first place, and then the EGR cooler, and then head gaskets! I keep reading about this sand sand sand and particulates issue and the oil cooler getting clogged where the coolant runs through it. From there, that coolant goes to the EGR. I presume my loss of coolant was the EGR blew and the coolant got out and down the EGR valve and got into the engine and burnt! If Ford knows that is the problem, then fix it! I found the site the other nite you are referring to and will be ordering my coolant filter kit Monday and have it overnighted! There does not seem to be anything else making these two things fail. Now, add all that sand from the casting of the block I guess and push it through all the rest of the motor and that sucks too! As stated, I LOVE my truck! I am 46years old, 29 1/2 years now in the Air Force with 9 months till retirement. I only drive the truck about 5k a year and it is paid for! I have already read another article where nearly 7500 of the new 6.7's just went back to the factory prior to sale with motor issues? I am REALLY hoping this coolant filter does the trick! They use it 24/7 on larger commercial vehicles! I have not had a single problem with this motor other than this so I am again, hoping this coolant filter solves the problem!

??again, I guess if Ford admits to the coolant filter or sand issue that must be acknowledging the flaw and maybe they would be liable? My dealership has been AWESOME to me on this entire process! With my vehicle being paid for and as clean as it came off the showroom floor, I will NOT be trading for a 6.7 Ford diesel (I learned my lesson-wait 3-4 years after initial production of any product before purchasing!!!!). I have considered a F150 fx4 king ranch but they just don't do it for me and towing my 7500lb Baja Outlaw boat!

 

I'd take my 6.0 falling apart once a week over a good running gas truck any day of the week. Once you go diesel, you don't go back.

Put that coolant filter on and you will literally **** at how much junk comes out of your motor when you change the coolant filter for the first time. Then you will see why they put these on. When the sand and junk clogs the oil cooler, the coolant can not pass through as needed and causes hot spots in the EGR cooler. This causes the EGR cooler to fail, and can cause headgakset issues (heat is bad past a certain point!)

My guess is if you've already had this stuff replaced, you probably have bad headgaskets. My dealer did the same thing to me, they have to follow the TSB. They start with replacing the coolant reservoir cap, then the EGR cooler, then the headgaksets, provided you still have issues with white smoke. If you don't, then it probably was just the EGR cooler.

Even a stock 6.0 should have headstuds (done right with the heads decked for flatness) and an EGR cooler/valve delete, for the utmost in reliability. Once you're out of warranty you might want to look into this stuff, or talk to your tech now and see if you can get this stuff done sooner rather than later.

The only bad thing I've heard so far about the 6.7's from Ford was on this site and it had NO proof to back it up. Go on youtube, there are vids of 6.7's with DPF deletes, EGR deletes, and urea deletes and straight pipes already. Spartan and KEM are already on top of it...