New EGR and Oil Cooler - Ford Powerstroke Diesel Forum

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post #1 of 16 Old 10-11-2010, 04:37 AM Thread Starter
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Smile New EGR and Oil Cooler

Well after reading a lot of postings about blow EGR coolers and stock oil cooler failures I decided to replace both. Now since I did not want a EGR delete need to stay emmisions legal. I went with a new EGR Cooler from Bullet Proof Diesel. I also used their new oil cooler system that eliminates the risk of cross contamination of your oil and coolant system. It also allows your oil system to flow at peak demands with out oil bypassing the filter. While I was in there that far I also replaced my HPOP fitting getting rid of the Quick Disconnect style and replacing it with a metal fitting that Ford upgraded. I also found my HPOP filter blow out and that was not a huge suprise either. I have a few pictures of the install that I will be posting once i get them off the camera. I will add to this posting as I put more miles on these new components.

2005 F250 Lariat 6.0 Powerstroke
Crew Cab 4X4 FX4
Upgrades to date:
Bullet Proof Diesel EGR Cooler
Bullet Proof Diesel Bumper Mount Oil Cooler
STC Fitting Upgrade
High Idle Mod

Upgrades Pending:
EDGE CTS Monitor w/ EGT Probe
SCT Tuner w/ Custom Tunes
Coolant Filter
AFE Stage 2 Si Intake
Powermax Turbo
4" Turbo Back Exhaust
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post #2 of 16 Old 10-11-2010, 05:13 AM
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Ive been looking at that bullet proof bumper mount oil cooler for some time now, cant wait to see your picks.

2004 F250
  • Zoo Dad Mod
  • High Idle Mod
  • Lost Cat Mod
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post #3 of 16 Old 10-11-2010, 05:17 AM
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Congrats on the new goodies! How was the install? Did you get the bumper mount or condenser mount oil cooler?

I have one of these kits waiting to be installed on my truck, after Elk season


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
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post #4 of 16 Old 10-11-2010, 08:45 AM Thread Starter
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Well Pics are loaded in my albums. The install was very labor intensive due to having to pull off the intake. Other than that it was easy just took a lot of time. I needed about three 8 hour days to completly have it done. I went with the bumper mount because I didn't have to equipment to recover and evacuate the A/C system. I was really pleased with the overall result.

2005 F250 Lariat 6.0 Powerstroke
Crew Cab 4X4 FX4
Upgrades to date:
Bullet Proof Diesel EGR Cooler
Bullet Proof Diesel Bumper Mount Oil Cooler
STC Fitting Upgrade
High Idle Mod

Upgrades Pending:
EDGE CTS Monitor w/ EGT Probe
SCT Tuner w/ Custom Tunes
Coolant Filter
AFE Stage 2 Si Intake
Powermax Turbo
4" Turbo Back Exhaust
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post #5 of 16 Old 10-11-2010, 09:02 AM
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Nice!!! Lets see some pics!!!!

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post #6 of 16 Old 10-11-2010, 10:19 AM Thread Starter
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Well as promised.



As I am sure many of you have viewed before here is the motor waiting new parts.



Here we have the new EGR cooler and the BPD oil cooler adapter installed just like it belongs there.



Dirvers side plumbing.



Passanger side plumbing.



Not to worry those oil spots are from the teardown portion





Oil filter before rock guard was installed. I also had to remove that angle brace it was rubbing the filter.

2005 F250 Lariat 6.0 Powerstroke
Crew Cab 4X4 FX4
Upgrades to date:
Bullet Proof Diesel EGR Cooler
Bullet Proof Diesel Bumper Mount Oil Cooler
STC Fitting Upgrade
High Idle Mod

Upgrades Pending:
EDGE CTS Monitor w/ EGT Probe
SCT Tuner w/ Custom Tunes
Coolant Filter
AFE Stage 2 Si Intake
Powermax Turbo
4" Turbo Back Exhaust

Last edited by FordPwrStroke4Life; 10-11-2010 at 12:34 PM. Reason: clairification on a pic
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post #7 of 16 Old 10-11-2010, 10:42 AM
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Thanks for the pics, looks great


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
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post #8 of 16 Old 10-11-2010, 11:06 AM
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I read somewhere that one of these types of oil coolers causes problems with your AC, that it makes it not able to get as cold, not sure if it was the condenser or bumper mount.
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post #9 of 16 Old 10-11-2010, 11:16 AM Thread Starter
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It is the bumper mount however all you have to do is change the orfice and bump up the charge over staock by about 6-12 oz and everything is fine. I choose the bumper mount vs. the condenser because in my opinion that design is just robbing peter to pay paul. as the air flows with the condenser mount it would hit like this condenser oil cooler intercooler then your raidator with the air only getting hotter with each stage. didnt make much sense to me. the only time i will be concerned with my bumper mount is on a hot day stuck in traffic sitting still

2005 F250 Lariat 6.0 Powerstroke
Crew Cab 4X4 FX4
Upgrades to date:
Bullet Proof Diesel EGR Cooler
Bullet Proof Diesel Bumper Mount Oil Cooler
STC Fitting Upgrade
High Idle Mod

Upgrades Pending:
EDGE CTS Monitor w/ EGT Probe
SCT Tuner w/ Custom Tunes
Coolant Filter
AFE Stage 2 Si Intake
Powermax Turbo
4" Turbo Back Exhaust
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post #10 of 16 Old 10-20-2010, 05:26 PM Thread Starter
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Well I have been driving for about a week now with the new oil cooler and egr cooler installed and I am pleased so far. The aspect I am most excited about is my truck no longer billows steam out the tail pipe like a 19th century locomotive. I am glad it was only the egr cooler. I was not ready ($$$) for a head stud job at this time. I am still kicking around the idea of doing it on my own. We will see I will need a whole week off of work for that project since this is my daily driver.

2005 F250 Lariat 6.0 Powerstroke
Crew Cab 4X4 FX4
Upgrades to date:
Bullet Proof Diesel EGR Cooler
Bullet Proof Diesel Bumper Mount Oil Cooler
STC Fitting Upgrade
High Idle Mod

Upgrades Pending:
EDGE CTS Monitor w/ EGT Probe
SCT Tuner w/ Custom Tunes
Coolant Filter
AFE Stage 2 Si Intake
Powermax Turbo
4" Turbo Back Exhaust
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