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Old 06-18-2019, 05:30 AM   #1
Dave W
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Ford 6.7 EGR Cooler

Curiosity questions.


How many of you folks have had to replace an EGR cooler. It rears it's ugly head with a check engine light and a P0401 fault code (Exhaust EGR Flow Insufficient). I've been clearing that code for about 2 years and it will last weeks or even months but it's about time to bite the ol' bullet and either DIY or *gasp* pay someone else.


About how many miles on your truck when done - I went over 100K? Appox. $$ it cost for replacement?
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Old 06-18-2019, 06:17 AM   #2
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I didnt say this but do a delete. Not saying where or how because its illegal. but in Florida or Michigan they have no emissions test. I Just heard you can do this but its only hear say. Wink Wink.
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Old 06-18-2019, 06:32 AM   #3
mazboy
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while in key west this winter i had the same issue. the mechanic went in and cleaned out the tank and reflashed it. so far, good.


of course it cost me a quick $900.00
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Old 06-18-2019, 06:43 AM   #4
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2012 F350 and had to have cooler core replaced @80,000 miles about $950.00 (dealer quoted $1400.00). 4 months later DEF heater throwing code for another $900.00 (didn't bother to check with stealer). I decided to go another route this time and am VERY happy I did. No more problems!
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Old 06-18-2019, 06:48 AM   #5
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Quote:
Originally Posted by mazboy View Post
while in key west this winter i had the same issue. the mechanic went in and cleaned out the tank and reflashed it. so far, good.


of course it cost me a quick $900.00
I don't know what truck you have but a Ford doesn't have a "tank" on it's egr cooler. Maybe that $900.00 was quicker than you realized.
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Old 06-18-2019, 06:52 AM   #6
mazboy
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actually the code was the same and it was the def tank issue but it worked.


as for what is going on with dave, here is a site:
http://powerstrokehelp.com/6-7liter/...er_failure.asp
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Old 06-18-2019, 07:41 AM   #7
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The EGR cooler on my 6.4 will never go bad or give any trouble. It’s laying in a box beside the DPF in my tractor shed.
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Old 06-18-2019, 08:07 AM   #8
Dave W
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Looks like some wallet pain is on the horizon either as a DIY or ocal guy.


That DEF tamk heater has an extended to 120,000 mile warranty on it and IIRC, 10 years, which ever comes first.


I am toying with an illegal act to remove these problems but I still have a Ford ESP to 136K and 18 more months. Being a JOB 1 truck, have potential RH head valve stem problems (EGR cooler is not covered under that ESP)
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Old 06-18-2019, 08:26 AM   #9
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Never a problem for our 6.7
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Old 06-18-2019, 08:46 AM   #10
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I can't speak to the 6.7, but on my 6.0 when the EGR Cooler failed at about 80,000 miles it was highly recommended that the oil cooler be replaced as well. IICC the service manager said that the two work in conjunction and that as one starts receiving restricted flow it impacts the other. At any rate he had to fight with the extended warranty company to get it approved. Total bill approached $3,000 about 8 or 9 years ago. You might want to ask your mechanic if the EGR and oil cooler system is similar on the 6.7. Although I would definitely consider what others have mentioned, be aware that you may be unable to have a dealer take your truck in on trade.
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Old 06-18-2019, 10:40 AM   #11
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Quote:
Originally Posted by Theunz View Post
I can't speak to the 6.7, but on my 6.0 when the EGR Cooler failed at about 80,000 miles it was highly recommended that the oil cooler be replaced as well. IICC the service manager said that the two work in conjunction and that as one starts receiving restricted flow it impacts the other. At any rate he had to fight with the extended warranty company to get it approved. Total bill approached $3,000 about 8 or 9 years ago. You might want to ask your mechanic if the EGR and oil cooler system is similar on the 6.7. Although I would definitely consider what others have mentioned, be aware that you may be unable to have a dealer take your truck in on trade.

Doing my homework on these EGR coolers have found out that the 6.0 and 6.4 engines are much more costly to replace the coolers - like 2X. The worst part evidently on the 6.7 is that the cooler tube to manifold bolts easily break but at least can be accessed for drilling out and installing Helicoils. This is the reason I may farm it out to a good shop
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Old 06-18-2019, 03:18 PM   #12
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My 6.7L was in and out of the dealers for almost 8 out of 10 weeks replacing the EGR cooler twice, the core once, two MAP sensors, MAF sensor, wastegate, wastegate solenoid, and then finally the turbo. All before 28k miles. Went another direction as I had an extended vacation pulling the Montana through 5 states. Haven't looked back. Ford told me when they couldn't get it right, that I could trade it. If they couldn't fix the one I had, why would I buy another one??!! Happy camper now with the truck I wanted!
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Old 06-23-2019, 09:28 PM   #13
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Quote:
Originally Posted by WeBeFulltime View Post
2012 F350 and had to have cooler core replaced @80,000 miles about $950.00 (dealer quoted $1400.00). 4 months later DEF heater throwing code for another $900.00 (didn't bother to check with stealer). I decided to go another route this time and am VERY happy I did. No more problems!
Same here. Went the other route and very happy with the results.
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Old 06-24-2019, 09:29 AM   #14
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I have no idea what "another route" might mean.
But anyone considering modifying their emissions systems should take into account the possible repercussions. For example, here is Texas take on it. I woiuld guess other states have something similar.



Texas law prohibits any person from selling, offering for sale, leasing, or offering to lease any vehicle not equipped with all emission control systems or devices in good operable condition. Violators are subject to penalties under the Texas Clean Air Act of up to $25,000 per violation. Buyers are advised to have the vehicle checked for all required emission control devices prior to purchasing a new or used vehicle.


Dealers likely will not take them on a trade in.
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Old 06-24-2019, 05:45 PM   #15
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I am a member on the ford truck site and there are lots of people removing the smog equipment from there trucks. Personally I am not a fan of doing that. My truck is going to remain stock and just spend the money to fix it if it has a problem. I live in Ca. so I have no choice but wouldn't make a difference to me where I lived. You can spend as much as $3,000 to buy the parts and tune and you need a tune to remove the egr. Not sure what you really gain by removing that stuff. Some guys say they get more power and better fuel millage. I don't believe that for a second.

But to each there own. I give them enough grief over there.LOL
I just don't want to smell someones exhaust or see that black smoke. B y the way that stuff gets on anything you tow.
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Old 06-24-2019, 07:56 PM   #16
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You can get more power no question. I have at least 50 different tunes I can load. A tune from no extra power to 350 extra horse power with EGR or without or with or without the DPF. My 6.4 can develop over 750 rear wheel HP. and over 1200 pound feet of torque. You loose 22% through the drive train. That is serious power. I use the 210 tow haul tune. I’ve used that tune for 10 years without any trouble.
Better fuel mileage, I’ve not seen it. I wouldn’t drive a 6.4 Ford stock. I’ve seen the difference. My truck tuned is a different truck a better driving truck. Much more responsive, way more power.
Would I tune a new truck? These trucks have been improved so much since mine was built, I doubt I would tune a new one.
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Old 06-24-2019, 08:54 PM   #17
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Quote:
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Would I tune a new truck? These trucks have been improved so much since mine was built, I doubt I would tune a new one.
Lynwood
You would....
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Old 06-24-2019, 10:12 PM   #18
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I would like to see one on the dyno. No one has posted a dyno sheet anywhere.

All this talk about more this and that means nothing. I also think a canned tune is so generic that if you could get more it's not the most nor is it the best bang for the buck. Then there is the hours of wrenching and buying plugs for the wires hoses and such. Personally I wouldnt buy a modified car or truck. If I was to sell my GT500 I would return the car to stock. Knowing full well he is going to put the mods I took off back on.
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Old 06-25-2019, 06:35 AM   #19
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Since the subject has come up, I've done a little more looking with more to come into cost vs benefits for just an ERG delete or a full delete including DPF, replacement exhaust and tuners.


An EGR delete is pretty inexpensive and about $200 plus tuner plus labor if not a DIYer
Add in the DPF and a full on tuner plus needed pipes and that EGR delete, you are looking at $2-$4000.
Versus,
A new EGR cooler at $250-$300 DIY/$750-$900 shop



Benefits - I looked for dyno result graphs but so far, couldn't find any. Verbiage claims are that power is better (seat of the owner's pants?) as is fuel mileage but I still didn't find 'real' numbers. Will you get better then the 18-20 mpg that I usually get on my 8360 pound CAT scaled truck, open road, no trailer, 12 mpg with the 12,000 5er hooked on? Beats me but I can buy lots of fuel for the Delta mpg difference or have 3-4 EGR coolers installed in the next 3-400.000 miles.


Legality of a delete - it isn't legal by both state and federal law. NY State is kinda loose as there is no yearly inspection/testing on a pickup at least through a SRW F350 (dually's, yes as they exceed 8500 pounds) but it can still get very expensive if they decide to do a roadside check - which the NYSP do occasionally conduct. I may also want to eventually trade this truck for another one and at a Ford/GM/Ram dealer



Twenty years ago - I would have done a full delete. Today, no. I just don't have the discretionary income for 'maybe it will help' items I had then nor do I need a huge fine to wipe those dollars out.


Your choice - I've made mine
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Old 06-25-2019, 07:30 AM   #20
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The figures I quoted were dyno by many people on several dynos. 1/4 mile times are down in the 12 second range. It’s takes a lot more power than stock to run that ET. I can tell by my seat of the pants duno I have way more power than stock. An 8300 pound truck that will spin the back tires at 50 MPH isn’t stock, mine will.
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