Doing an EGR delete and rebuild oil cooler - Ford Powerstroke Diesel Forum
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post #1 of 17 Old 07-01-2010, 06:01 AM Thread Starter
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Doing an EGR delete and rebuild oil cooler

Where are you guys getting the best deal on the oil cooler rebuild kits, or are you just buying new ones? We're doing the DIY EGR delete to save some money, I have a friend that is a welder and can weld up the cooler, I'll weld a plug in the up pipe, I'll just need some hose and the 180* bend for the coolant line. I'm also installing a coolant filter on this truck too.

What else am I missing?


2006 F350 SOLD
* KMC XD Monsters wrapped in Hankook ATM's
* 08 style mirrors
* 4" TB exhaust
* SCT X2 with Gearhead, PHP and ID tunes
* Edge Insight CTS
*Full Bulletproof Diesel kit with remote oil cooler
* Blue FPR spring
* 6.4 Banjos
* Repaired FICM by BPD
* Dfuser coolant filter
* Stage1 MTW turbo



New truck has a Cummins and a handshaker

Is it 2016 yet?
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post #2 of 17 Old 07-01-2010, 06:05 AM
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you are going to want to take the up pipe out and take the scoop out of the pipe. then just weld the hole shut. and i used a small preformed hose to make the 180degree bend for the oil cooler to the intake hose.

2004 F250 6.0 CC 4x4 SCT with custom tunes
zoodad mod, head studs, Home Brew EGR delete, 5" MBRP striaght exhaust, 05 headlight Conversion
HID Head and fogs.
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post #3 of 17 Old 07-01-2010, 06:06 AM
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A BUNCH of gaskets.

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 #4 of 17 Old 07-01-2010, 06:08 AM
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post #5 of 17 Old 07-01-2010, 07:22 AM Thread Starter
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Its an 04 so I don't think it has that baffle in the up-pipe, but I will be sure to look and cut it out if necessary. I wonder if I can find just a gasket kit for the intake manifold and the oil cooler? That way I won't be running around like a fool getting them while I'm trying to put it back together


2006 F350 SOLD
* KMC XD Monsters wrapped in Hankook ATM's
* 08 style mirrors
* 4" TB exhaust
* SCT X2 with Gearhead, PHP and ID tunes
* Edge Insight CTS
*Full Bulletproof Diesel kit with remote oil cooler
* Blue FPR spring
* 6.4 Banjos
* Repaired FICM by BPD
* Dfuser coolant filter
* Stage1 MTW turbo



New truck has a Cummins and a handshaker

Is it 2016 yet?
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post #6 of 17 Old 07-01-2010, 07:56 AM
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Quote:
Originally Posted by 2006PSDSD View Post
Its an 04 so I don't think it has that baffle in the up-pipe, but I will be sure to look and cut it out if necessary. I wonder if I can find just a gasket kit for the intake manifold and the oil cooler? That way I won't be running around like a fool getting them while I'm trying to put it back together
I bought an oil cooler rebuild kit off of ebay for about 165 shipped.

The oil cooler rebuild kit comes with all the o-rings and gaskets to rebuild the oil cooler. The oil cooler rebuild kit part # is 3C3Z-6A642-CA, and you can get intake gasket kit part # 3C3Z-9433-AA and it includes the turbo mounting hardware.
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post #7 of 17 Old 07-02-2010, 06:27 PM
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I bought my oil cooler from my dealer. I just told the parts guy that I wanted to buy local rather than buying it online so he asked me how much they were going for and I told him about $200 online, he said he would do it for $225 so I got it from him. The intake gaskets run about $90.

Bob
2004 F250 6.0 Diesel
Crew Cab Short Bed
2 Wheel Drive
105,000 Miles

1995 Chevy K1500
6.5 Diesel
335,000 Miles
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post #8 of 17 Old 07-03-2010, 04:57 AM Thread Starter
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Quote:
Originally Posted by Ben27b View Post
I bought an oil cooler rebuild kit off of ebay for about 165 shipped.

The oil cooler rebuild kit comes with all the o-rings and gaskets to rebuild the oil cooler. The oil cooler rebuild kit part # is 3C3Z-6A642-CA, and you can get intake gasket kit part # 3C3Z-9433-AA and it includes the turbo mounting hardware.
Quote:
Originally Posted by fonecop1 View Post
I bought my oil cooler from my dealer. I just told the parts guy that I wanted to buy local rather than buying it online so he asked me how much they were going for and I told him about $200 online, he said he would do it for $225 so I got it from him. The intake gaskets run about $90.
Thanks guys, I will probably start tearing into it this week sometime. I want to verify that its the cooler and not the HG's


2006 F350 SOLD
* KMC XD Monsters wrapped in Hankook ATM's
* 08 style mirrors
* 4" TB exhaust
* SCT X2 with Gearhead, PHP and ID tunes
* Edge Insight CTS
*Full Bulletproof Diesel kit with remote oil cooler
* Blue FPR spring
* 6.4 Banjos
* Repaired FICM by BPD
* Dfuser coolant filter
* Stage1 MTW turbo



New truck has a Cummins and a handshaker

Is it 2016 yet?
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post #9 of 17 Old 07-03-2010, 06:48 AM
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Get the rebuild kits either from Ebay, the dealership or BulletProof Diesel. The rebuild kits are about $200 for the new cooler block and gaskets. You will need new intake gaskets and EGR cooler gaskets as well, which are about $100.

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 17 Old 07-03-2010, 06:53 AM
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don't forget to get the stainless screen underneath the oil cooler. They fall apart over time and should be replaced.

Diesel Dan

10,000 LAKES CHAPTER MEMBER


2003 F350 Crew cab long box, FX4, 6.0, torqshift, Lariat.

Last edited by dieseldan2005; 07-03-2010 at 01:24 PM.
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