....and I have a few thoughts, which I haven't ran across yet, which might be beneficial to someone takling this the first time.
1. If you don't have an air ratchet, there is only one substitute. Forget about using a regular ratchet of any kind on the v-clamps behind the turbo, unless you enjoy spending an hour going 1 or 2 clicks at a time. I have an air ratchet, but when working on it at 10:00 p.m., can't really be waking the neighbors. Plus teh space is so limited in my garage with teh beast all the way in, I can barely walk around it as is. I was skeptical, especially as we're talking Harbor Freight, but figured I can always return for the $29.99 price tag. I am pleasantly impressed....it did the trick, maybe even easier than my air ratchet with fighting the air hose. I like this tool so much, I wouldn't think of returning it.
2. I read about the people with sore backs, aches and pains from leaning over and working on this. I'm doing this with a torn rotator cuff, that is scheduled for surgery Feb 14th.....and this is a physically demanding job, only as far as all the reaching and bending over. A sturdy step stool about the height of an upside down 5 gallon bucket is perfect. The 5 gallon bucket doesn't work well....it will slip out under your feet when reaching behind the turbo, and I'm 6' tall.
3. Prepare some sort of cushioning to lay across the front of the engine bay. Half to protect it, half to protect you! That hood latch hurts.
4. Wiring harness....I haven't read a whole lot about what to do with it during the egr delete, usually there is no mention of it. I unbolted the FICM to move it a couple inches to the side, unplugged the 8 connectors, and used a couple bungee cords to support it a bit higher. Manifold cam out fine this way.
5. Labor time. Various egr delete manufacturers will quote time frames of 6 to 12 hours. Let's be real here. Even with a torn rotator cuff that is 'tolerable' for now, I am a former USAF crew chief and aircraft mechanic. I work on gas and diesel engines in Class 8 trucks. Those time frames are accurate assuming you are simply doing teh job, swapping out the parts. Start calculating in teh rest of the items not mentioned. Like, are you going to re-install that turbo stand that is caked with oil on one side of it? Or will you spend the time to clean it....and maybe paint it with some engine high-temp paint? Doing the oil cooler, and I can see I will be spending 30 minutes cleaning just the cover. The engine valley.....I'm thinking 20 minutes with a brush and a shop vac. Plugging 16 intake ports with carefully rolled up paper plugs? Another 20 minutes. Cleaning all the bolts, the one's that will be re-used? How about the prep work, during the flushing procedure? I installed the Furano valves in the block drains, but you have starter R&R involved as well. Although 20 years ago I would do this start-to-finish non-stop starting on a Saturday morning, I'm not that young anymore. Properly done, with items properly cleaned along the way, I'm going to estimate 18 hours for the egr delete and oil cooler. (That's AFTER you have spent the better part of a day flushing your system.)
General thoughts: I'm convinced the problem with the Ford 6.0 Powerstroke is 100% NOT International's fault. If this engine were installed in a class 7 truck, there would be a doghouse access panel to easily access the back of teh engine, making servicing the egr system much easier. Ford shoved this engine in this truck...well...face it, WE wanted a pick up with a powerful diesel, right? Well, Ford erred in using the wrong coolant. They should have followed International's guidelines. Additionally, I think ANY turbo diesel needs to be run on synthetic oil only. Just due to the turbo heat, oil coking, etc. I just inspected my 172,000 mile egr cooler......water flows freely through it, and other than slight soot inside, no passages appear clogged. I was a bit shocked by the number of welds on the damn thing. (This is a 2006, square cooler.) Oil cooler inspection coming up within the hour....I'm preparing for the huge mess of oil as I remove it. I have a plastic garbage bag ready to set it into, right next to the engine......Yes, the Forum has saved me from doing what most have ended up with....a long trail of oil across the floor!