EGR Issues related to High Pressure Oil Coupler? - Ford Powerstroke Diesel Forum

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post #1 of 13 Old 06-02-2012, 11:23 AM Thread Starter
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EGR Issues related to High Pressure Oil Coupler?

My 2005 F250 6.0 broke down On Interstate 80 and was towed to a Ford Dealer in Elko NV. After waiting for two days in Elko they told me that it was the High Pressure Oil Coupler and that 4 of the 8 dummy plugs were leaking. They replaced the coupler and all of the plugs, charged the batteries and sent me on my way. 300 miles later I get the CEL and the ABS lights, lack of power, smoke etc... I was able to limp it home. I was pulling a 4000 lb trailer. After I unhooked the trailer it was as if nothing had happened, drove great, no smoke, power, the CEL stayed on but the ABS light is off. I took it to my local Ford dealer. They haven't told me the whole story but the service manager said it had lots of codes in memory pertaining to the injectors and a new code, PO 404, pertaining to the EGR. My question is this, would the work that was done changing out the High Pressure Oil Coupler, tubes and Dummy Plugs foul the EGR? and would the work also cause injector codes to be in memory?
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post #2 of 13 Old 06-02-2012, 11:48 AM
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Nope that wouldnt foul the EGR. EGR failures are common. Too bad they didnt catch it when you had the other stuff done.

I recommend deleting it if you're in a state that doesnt emissions test diesels.

If you are I recommend the Bulletproof Diesel EGR cooler

Email: Dave@powerstroke.org
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post #3 of 13 Old 06-02-2012, 07:17 PM Thread Starter
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I priced out a EGR valve NIB from Motorcraft at $277. It looks like a pretty easy job to replace, especially for a trained mechanic. Maybe books at 1 hr? I've read alot of posts here where EGR jobs have been $1,000 or more. What are they going to come at me with, Manifold cleaning, EGR cooling tube replacement etc???

I dont have emission testing (yet). I see different kits, some that require removal of the turbo and others that just have a plug for the EGR. Are they all good? some not so good, some not good?
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post #4 of 13 Old 06-03-2012, 03:41 AM
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Its generally not the valve thats the issue. Its cooler failure. If you dont have emissions delete the cooler

Email: Dave@powerstroke.org
2011 F150 Ecoboost Crew cab lariat. Custom tunes from KEM and 5Star, and Unleashed
2012 F150 Crew Cab Ecoboost stock for now-Totaled March 12 2015
2006 F250 ECSB Lariat 4x4

Leveling kit, 315/70/17 Kelly TSRs on Method race wheels
ARP studs and OEM gaskets done by Renegade Diesel
ECM and Atlas 40 FICM tuned by Bill at PHP SCT tunes by Truck Source Diesel. Gearhead, Innovative, Wildman and Tyrant diesel
Flowmaster/MBRP Hybrid Exhaust
Edge Insight CTS
Coolant filter
Bulletproof diesel FICM EGR Delete, Oil Cooler and Water Pump, and Light bar.
Dually LED lights from Stealth Automotive/Xpedition Outfitters
No Limit Fab 6.0 Cold Air Intake
http://www.bulletproofdiesel.com/default.asp
http://nolimitfabrication.com/
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post #5 of 13 Old 06-03-2012, 07:04 PM Thread Starter
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I'll have to get this fixed before I can do the delete to abide by my extended warranty which still has two years and about 40,000 miles until it expires. Reading my warranty I see that the EGR is listed under electronics and is not covered. The warranty does cover "Hard Lines." Would the EGR cooler be considered a hard line?
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post #6 of 13 Old 06-04-2012, 06:44 AM
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Sounds like your EGR valve was sticking... Pull it and give it a thorough cleaning with brake fluid being careful not to get it into the internals of the valve itself. It's a pain to get it out, but I'll venture to say it's REALLY dirty...

Dave's assessment is spot on for a failing EGR cooler, but that doesn't sound like your problem. If the cleaning procedure doesn't fix the problem, replace the valve.

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post #7 of 13 Old 06-06-2012, 09:50 AM Thread Starter
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I learned today that it needs an EGR Valve and a Fuel Injector Pressure Regulator Valve.
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post #8 of 13 Old 06-08-2012, 04:37 PM Thread Starter
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Rat Farts.... Called a few ago and was told that the EGR was wet. Just as suspected, EGR cooler needs to come off. I'll probably have to go to war with the Warranty Co. if I want to put on the Bullett Proof version. My service manager says that this particular company isn't keen on owner supplied parts without a Ford part number and thinks that it will void the warranty in the future... Even though it's a far superior upgrade and will probably cure the issue forever. I'll have to call them myself to make sure I'm not getting a sales pitch... Thanks for your help guys.
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post #9 of 13 Old 06-11-2012, 05:54 AM
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Sucks to hear that they won't allow you to use the BPD EGR cooler. Keep us posted on what you find out from your warranty company.

Shawn Carlson
EvilEye@powerstroke.org

Proud Navy Vet
2005 F250, CCSB, 6.0 PSD, FX4 (The Sweet Unit is white)
2008 F350, CCLB, 6.4 PSD (Brad-the wife's truck is black)




Engine Mods:
Fluidampr
CCV Reroute (Reinstated)
4" MBRP Exhaust
MTW Stage 1 Turbo
Bulletproof 53V FICM
BulletProof EGR Cooler
BulletProof Water Pump
Riff Raff Intercooler Boots
Gogo Diesel Direct Drive Solenoid
BulletProof All-Aluminum Radiator
BulletProof All-Aluminum Intercooler
BulletProof Oil Cooler System w/ Bypass Filter
SCT w/ Custom Tunes (TSD, DJ's, Innovative, Gearhead, QuickTricks)

Exterior Mods:
Bilstein 5100 Shocks
Icon Adjustable Trac Bar
Firestone RideRite Air Bags
BDS Dual Steering Stabilizer
Aluminum Finned Differential Cover
Reese 16k Manual Slider 5th Wheel Hitch
Icon 2.5" Leveling Kit w/ F-350 rear blocks
20" BMF Novakanes wrapped in 33" Nitto Terra Grapplers
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post #10 of 13 Old 06-12-2012, 02:36 PM Thread Starter
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I just came back from the dealer. It's now escalated to rebuilding the turbo, due to it being "gummed up" as he put it. He also said that they need to flush the system. He's waiting to hear back from the warranty co. for approval on the work.
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