EGR Cooler Replaced Still Puking & Overheating - Ford Powerstroke Diesel Forum
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Old 11-17-2007, 04:02 PM
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EGR Cooler Replaced Still Puking & Overheating

I'm new to the forum so I will start with a hello to everyone. This is a great forum. I wish I would have found it a year ago.

My problems all started about a year ago. It started puking coolant climbing grades pulling my 17k loaded toyhauler. I do have the Banks system and exaust. It would heat up the fan would kick in and it would cool right down. It got progressively worse on each trip.

About three weeks ago, I started it up and it blew the white smoke I've read so much about. I removed my Banks box and gauges and called my dealer for an appointment. It took two weeks just to get it in. I assumed it was head gaskets because I had heard about them. To my suprise they said it was the EGR cooler. After reading in this forum I understand how that all works.

I got my truck back yesterday, and today I went on a test run with my trailer. Everything was going fine, and the temperature was runing in the middle. I got out in the foothills near us, not running hard at all, and all of a sudden I noticed it was in the red, so I let off and started to pull over. It immediately cooled down. I popped the hood and found that it had puked some coolant. I decided to go on. I drove on through the foothills for another 20 miles and everything went fine. I decided to take Hwy 58 out of Bakersfield, CA where there are some steeper grades. I started climbing some grades taking it easy because of my concerns, and it was doing fine. Then all of a sudden just like before it got hot. I backed off some and it cooled down quickly. I could hear the fan so it is not that. It did it about four more times before I finally found a place to turn around. The rest of the way home everything was fine.

So now I assume I also have head gasket or stud problems. Is there anything else that will make it behave like this? I read about the ARP studs and plan to use them, if they turn out to be the problem.

I would appreciate any input from you guys. It sure sucks to listen to all my Chevy friends, especially my brother.

Last edited by wtprez; 11-18-2007 at 11:26 AM. Reason: show signature
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Old 11-17-2007, 04:09 PM
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There are ways to prevent your EGR cooler problems. Start off by letting us know what year your rig is as there are some differences from the early to late build 6.0s.

If the dealer didn't replace the oil cooler along with the EGR cooler that is the root of your problem. The oil cooler plugs up which slows down the coolant flow through the EGR cooler causing it to overheat and eventually pop. The only real way to prevent EGR cooler problems when towing heavy loads is to bypass the cooler altogether. Trucks that have this done are usually very dependable.
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Old 11-17-2007, 04:27 PM
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It's a 2005 F350.

They did not replace the oil cooler. I thought that was strange when I picked it up. I read that they usually replace them both. I even mentioned something to the service writer, but he didn't have a clue about it.

I read about the EGR delete. I was thinking about that.

Last edited by wtprez; 11-18-2007 at 11:28 AM.
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Old 11-19-2007, 11:32 AM
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I called my dealer today to get my truck back in. The service writer said that there are certain procedures they must go through on these waranty issues. From reading on this forum, it seems like the procedure is to replace both the EGR and oil cooler whenever one is bad. What is the case?
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Old 11-19-2007, 04:22 PM
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Tell him to proceed on and replace your oil cooler, and when it still pukes then the head gaskets. Some tech's know WTF is going on, some don't. Your tech should be able to hook it up to IDS and go for a ride and see if your oil cooler is working correctly or not. Sounds like he's being lazy or doesn't have a clue.
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Old 11-19-2007, 08:08 PM
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Thanks. My problem is I need this fixed for a New Years trip to the Imperial Dunes. At least they didn't tell me it was going to be another 2 weeks to get it back in.
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Old 11-19-2007, 08:16 PM
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You go up the grapevine at all?
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Old 11-19-2007, 08:57 PM
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Yes. My in-laws live in Orange County, and we normally go that direction to the Imperial Dunes. There are some good grades there too. When everything was working right I never got below 50 with my 17k trailer. I even made a couple of trips with a 15' quad trailer with 4 quads behind my fifth wheel. I decided to quit that before I got a ticket. The commercial CHP looked me over good on one trip, but he passed me up. My heart was thumping though. I had to be pushing 20k. It really towed nice, and the quad tralier had brakes too so it stopped just as fast. I'm sure that didn't help my truck, but they can't deny it's a bad design.
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Old 11-19-2007, 09:24 PM
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I forgot Imperial is also Glamis. I usually head out there a few times a year but spend most of my time at Ocotillo. How is your tranny holding up?
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Old 11-19-2007, 09:37 PM
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So far so good with the tranny. We've thought about Ocotillo Wells but haven't made it there yet. We actually go to Ogilby which is just off of the North side of I8 on the East side of the dunes. Not quite as crowded Glamis and more family oriented. I have rode my quad to Glamis from there, great ride.
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