The factory 6.0L Powerstroke EGR cooler is a common failure point, especially when the oil cooler plugs and restricts coolant flow to the EGR cooler. When that happens, owners may see coolant loss, white smoke/steam, degas bottle puking, or repeated EGR cooler failure.

Bullet Proof Diesel EGR Coolers are the upgraded replacements for 6.0L Ford trucks. They use stainless steel tubing, vacuum-brazed and TIG-welded seams, and a design built to reduce stress and improve reliability. This isn't smoke and mirrors. Bulletproof EGR Coolers are time tested and have been proven to perform and last over decades of use.

Check Them Out:

Bullet Proof Diesel Round 6.0L EGR Cooler (for trucks built BEFORE 9.22.03): https://www.riffraffdiesel.com/bullet-proof-diesel-round-6-0l-egr-cooler/

Bullet Proof Diesel Square 6.0L EGR Cooler (for trucks built AFTER 9.22.03): https://www.riffraffdiesel.com/bullet-proof-diesel-square-6-0l-egr-cooler-03-07/

Why upgrade?

Compared to the factory Ford EGR cooler, which has a weak stack plate cooling exchanger design, famous for cracking, the Bullet Proof Diesel units add more than twice the coolant capacity, has thicker cooling tubes, and all-welded construction. They also carry a lifetime parts-only warranty and are California CARB compliant.

 

Key details

• Multiple styles available for all year 6.0L trucks
• Thicker cooling tubes
• More than 2x coolant capacity
• Vacuum-brazed and TIG-welded seams
• Gaskets not included
• Refundable core charge applies

Tip: Don’t skip the oil cooler

We strongly recommend replacing the engine oil cooler at the same time. The oil cooler feeds coolant to the EGR cooler, so a restricted oil cooler can kill a new EGR cooler all over again.

 

Install reality:

Remove the intake/EGR components, remove the failed square EGR cooler, replace the required gaskets, install the Bullet Proof Diesel cooler, reinstall the intake components, refill and bleed the cooling system, then pressure-test and check for leaks.

 

Bottom line: If you’re searching for a 6.0 Powerstroke square EGR cooler upgrade, this is the emissions-compliant, long-proven replacement.