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Old 12-22-2011, 04:05 PM
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DIY EGR delete?

Has anyone done this?
Complete EGR removal write up

If so what size freeze plugs do I need? My egr cooler crapped today and I need to do this tomorrow. Also I read some other people weld either end of the stock cooler and put it back in. Are there better benifits to that versus the link's method?
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Old 12-22-2011, 05:35 PM
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To me it was less work to put plugs in my cooler than to do what the link did. Also they say the up pipe will eventually break because it has 2 flex joints and is no longer supported by the egr cooler. I didn't use freeze plugs in my stock cooler but I did weld plugs in the ends of mine. I don't recall the size other than both ends were different. We made the plugs out of stainless to fit snug and tig welded them in. I did it because I wanted it to look factory and have heard stories of leaks from some of the other setups. I wasn't going to spend the big bucks for the bullet proof delete kit that is the same thing. Since the exhaust is blocked the coolant will be contained if it blows but since there is no exhaust flow though it now I doubt it will ever blow now. I'm not worried about it clogging up either as the passages in the cooler are pretty large. Since yours already blew out you will have to block both ends of the cooler the keep you from loosing coolant. I personally didn't like the freeze plug idea. Good Luck

Last edited by ovrtrn; 12-22-2011 at 05:43 PM.
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Old 12-22-2011, 09:18 PM
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Thanks for the reply, any other ideas?
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Old 12-23-2011, 02:00 PM
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the number I have for the freeze plug is dorman 555-093. that should fit in the rear, not too sure about the front of the cooler
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Old 12-23-2011, 02:17 PM
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If you install and weld up freeze plugs then you can just reuse the stock EGR cooler. The exhaust side freeze plug is rather easy to find, the intake side one is a little goofier. It is possible to do and would work just as well as doing a full delete.

If it was me I would just try and block off you stock EGR cooler. Here's a kit on Ebay that has the plugs in it.

2003 - 2007 6.0 FORD Diesel NEW EGR Cooler Block OFF Kit | eBay
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Old 12-24-2011, 11:34 AM
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it's a shame you can't read the p/n off of that plug for the intake side. I know that guy uses dorman plugs too
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