EGR cooler failed now I have questions about my options to fix my truck? - Ford Powerstroke Diesel Forum
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Old 08-21-2011, 02:33 PM
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EGR cooler failed now I have questions about my options to fix my truck?

OK, so now even with a great delta ( 4 deg ) my EGR cooler has poped. I noticed The truck was loosing coolant at a very slow rate over the last month. I looked inside the EGR cooler hole and found wet goo. This is soot mixed with coolant. I am debating rather to weld up my cooler or to get one from this websight.

Egr Delete Kit, Ford Powerstroke 6.0, F250, F350, F450, F550, Excursion and Econoline Custom Diesel

Has anyone else here ever welded up an egr cooler? Are they made out of stainless steel? I have a tig machine and I am sure of my skills, but I need this to work right the first time. I don't have a ton of cash for this job and I can't have the truck down for more that a few days.

I am also planning for an STC fitting update. What else do I need other than a turbo mounting hardware kit?
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Old 08-21-2011, 02:50 PM
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It is stainless steel. Most of the ones I have seen welded up have used a freeze plug.
I have a delete very similar to that one you have linked. You know what everyone says..."If you don't have emissions testing, delete it"

The STC fitting replacement would require a new HPOP cover gasket (if the kit doesn't come with one) and the turbo mounting kit. You will need a little RTV for the rear corners of the HPOP cover, and when you go to remove it, slide a razor blade under the back two corners to cut the existing RTV.
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Old 08-23-2011, 09:36 AM
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Thanks, for the input. I have all my parts now. I am going to remove the cooler and weld up both ends with 1/8 inch plugs that I will make. I really don't trust a freeze plug especially on the exhaust side. I did find out that the 15/16 crows foot you need to torque the STC update fitting is a rare bird. The set at sears skips it entirely and goes from 7/8 to 1 inch. As a plan to keep bolts from falling down the back of the engine I am going to stuff it with rags and have a magnet handy just in-case. Would you use blue Loc-Tite on the HPOP bolts?
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Old 08-23-2011, 09:50 AM
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Nope. Just torque them down to spec.
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Old 08-23-2011, 10:09 AM
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Quote:
Originally Posted by HAM_RADIO_MAN View Post
Thanks, for the input. I have all my parts now. I am going to remove the cooler and weld up both ends with 1/8 inch plugs that I will make. I really don't trust a freeze plug especially on the exhaust side. I did find out that the 15/16 crows foot you need to torque the STC update fitting is a rare bird. The set at sears skips it entirely and goes from 7/8 to 1 inch. As a plan to keep bolts from falling down the back of the engine I am going to stuff it with rags and have a magnet handy just in-case. Would you use blue Loc-Tite on the HPOP bolts?
With the HPOP fitting upgrade kit it should come with the jig for proper alignment, so you wont need the crows foot. You can tighten the jam nut before installation. I would not use Loc-Tite. Be very carefull when putting the pump back in to make sure the bolts that connect the new fitting to the branch tube screw in easily! Almost should be able to run them in with your fingers. Have seen guys try and pry on the branch tube adapter and break branch tubes. ALL BAD!
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