BulletProofDiesel EGR Cooler (& new oil cooler)

[howell_jd]

Looks like I'm joining the ranks of those with a failed EGR cooler...

On Sunday night the truck threw the dreaded P0404 code. I noticed no performance issues and no check engine light came on either. On Monday morning, I opened the hood and added a little coolant - it looked a little low but I had some work on the coolant lines that provide heat to the water heater in the camper part of the EarthRoamer so I wasn't too worried (but I was a little worried). I also unplugged the EGR valve and then plugged it back in as I didn't really have time to pull it and check it out.

...and then my worries began...

After a clean start and pulling out the drive and down the street a bit the truck began to blow white smoke (it didn't smell sweet but did burn my eyes) and lost power initially. After I shut down and pulled off the road I looked at the coolant level again but couldn't really tell if anything had changed (it had been running a whopping minute or so - I usually let the coolant temp get to 112 before I pull out - that seems to let the truck have better acceleration...I don't know why). I restarted and more white smoke but I had power, there was the P0404 still so I cleared it. After getting down the road one block there was no more white smoke but there was now black smoke when I pressed the throttle hard like from a stop. I had to fill up the diesel tanks, run a few errands, return a few things, exchange a few things...Columbus Day off. The truck seemed to run fine but still there was that lingering doubt.

On Tuesday AM the truck had no white smoke at start up and I let the engine get a little warm as usual before heading to work 35 miles away. I watched the gauges and while it seemed to have a little higher spread between the EOT/ECT it was only 13 degrees and I was driving 65 over the hilly roads and through some recent construction. At the end of the day though I got the white smoke pulling out of the parking lot and there was that P0404 code again. I made it home and called the only BulletProofDiesel shop in Mississippi.

Acey's Auto in Jackson has taken care of me. I have a good relationship with Watson Ford in Jackson but I really didn't want to replace the Ford EGR cooler with a Ford EGR if I could avoid it. If I had a bit more money I think the Ford oil cooler would be replaced with a BPD oil cooler too but I am getting a BPD EGR cooler and stock oil cooler. I do have a coolant filter and oil bypass already installed. I just changed the oil on Monday too drat!

Looks like that mixed diesel/gas coolant episode finally killed the oil cooler in my truck. When I fixed the error of that event and had the coolant tested it came back with a report of much solder and other contaminants in the relatively new mixed coolant (they just filled the radiator not the whole system with gas engine coolant). My subsequent flush took 15 cycles before it was clear...and it started off muddy green (not from oil - I had it tested).

So...I'll have a BPD EGR cooler and a stock oil cooler with the coolant filter and oil bypass to protect it. The truck is just a bit south of 65,000 miles on the original EGR and oil coolers it seems (according to the OASIS). The EGR valve was replaced in March 2005 before I bought it.

I bought it at 41,000 miles in December 2005 after it returned from a 2 year around the world trip so all things considered I'm impressed. I'd be happier not to have to get the work done (or at least to have some time to do the work myself and cut the cost in half) but like I said earlier - Acey's Auto in Jackson, MS part of the BulletProofDiesel supported repair shops is taking care of me.

Thank you guys!

Jonathan

 

[howell_jd]

After reading this again it looks like an ad to me. That's not my intention. Just frustrated that I don't have the time to get the work done myself so I'm glad there's a place that can get the work done for me. They were a busy shop today. I guess that's good for business - and perhaps an indicator of maintenance given to southern Mississippi vehicles...wait a minute - I resemble that remark now! D'Oh!

JDH

 

[shortbus4x4]

As a mechanic all I can say is thank god for Ford engineers, they keep alot of us working.

 

[Rot Box]

There is a time when it is just better/smarter to have an expert do the work and it is good to hear you found a shop you can trust--that is rare these days it seems. The EGR cooler failures are all too common and its good you are going a better route than just installing another problematic Ford cooler. It has been said the 6.0 is an incredible motor once all of its shortcomings are sorted out.

Best of luck and please keep us updated with how your new cooler turns out :bike_rider:

 

[howell_jd]

I picked up the truck today. It threw two more codes but I think this was from engine work not a new fault (Crankshaft Position Sensor and Camshaft Position Sensor). The truck ran fine (great) from the shop home. The guys at Acey test drove it too. I called them when I got home just to let them know I had seen them as a precaution in case I need some more help later. I cleared the codes out and they haven't come back (yet?).

I will say that at least the EOT/ECT is running much tighter than before (and cooler too). I'm going to change the coolant filter out as well even though it is still flowing.

Sorry no pics this time. The guys at Acey told me the EGR was leaking in its guts so it was likely a solder point failure. Now I will keep my fingers crossed that I didn't stress the headgaskets. Please please please.

Jonathan

 

[UrbanCummin]

Hope the new cooler works out for you but why did you not just do an EGR delete when your factory cooler failed?

 

[howell_jd]

First and foremost a post 2003 diesel engine with an EGR delete is illegal to operate on US highways. While the primary indicator (its omission) is easily overcome with the BPD EGR cooler delete (it's spot-on visually identical to the stock EGR cooler), as a US military officer I may find myself assigned to a location where the requirements of operating a vehicle include an emissions check that exceeds a perfunctory visual check.

I do however find the reasoning that an EGR is an emissions system to be invalid as decreased fuel economy causes greater usage of fuel which increases emissions! I do not have to register my truck anywhere other than Texas (my state of residence according to the US Army - and which has OBD emissions checks including the EGR and a sniffer test) but I would still have to pass the safety inspection which might include emissions testing; certainly visual and perhaps a sniffer test. At this time I do not have to pass even a visual test for EGR in Mississippi but Texas does have these requirements so I would be in violation of my registration to go with an EGR delete.

Second (while a marginal justification at best), the EGR cooler is a "messenger" of oil cooler problems. Ultimately, my digital gauges should indicate rising oil temperatures and a separation of coolant/oil temperatures that accompanies a clogged oil cooler. That being said my coolant/oil temperatures were on the high side of the 15 degree separation as a result of the truck's size to begin with and 6.0's run a bit on the warm side anyway. It was (not) nice to have an additional indicator of trouble (not nice to have the trouble...nice to know that there was trouble in advance of head gasket failure!).

Ultimately, I can always do an EGR delete by welding shut the up-pipe from the exhaust manifold later when I know I won't have emissions testing. Of course that doesn't change the fact that it is illegal so I'm unlikely to take this step in any case.

I promise not to turn in anyone who might have an EGR delete but I will share a beer with the fellow who fails a check and wants to lament "the man" keeping him down!

Jonathan

 

[howell_jd]

...By the way, immediately after the repair my fuel economy improved from 12.5mpg to 13.5mpg. I got 12.5mpg on the way from Mississippi to Colorado before the EGR failed. I got 13.5mpg on my trip from Mississippi to Kentucky (Fort Knox) last week. Getting the EGR valve cleaned probably made some contribution if not most.

Jonathan

 

[Saline]

Sorry to hear about your troubles. The EGR/oil cooler issue is probably the biggest problem with the engine. How long had your coolant filter been on? If and when mine goes I will go with the BPD setup and I intend on switching the coolant from Ford Gold to the stuff International uses, ELC. There has been discussion as of late that the Ford Gold coolant can gel a bit as it is exposed to the high temps in the EGR cooler, in turn helping to hasten the demise of the factory oil cooler.

My 6.0 Powerstroke has been great so far (knock on wood) but I still worry about the EGR/oil cooler stuff, especially when we are in the middle of nowhere.

 

[howell_jd]

I have had the coolant filter since June at about 55k miles. I got it after my lower radiator hose failed going to see my grandmother for her 90th birthday party in March. I went to the Ford dealer (not my regular Ford shop) and was able to buy a new hose but they were completely backed up in the service department...the birthday party was WAY too important to take on the job myself and I would have to drive my own family back home after the celebration. SO...I took it to my parents' "trusted" auto shop where they begrudgingly accepted my previously purchased hose (they wanted me to buy through them even though they would have had to buy from the local Ford dealer) and assured me they would use the proper coolant (I did not buy Premium Gold from the dealer and I SHOULD HAVE). The auto shop used universal auto coolant and I didn't discover this until later - that is entirely my own fault too as the universal coolant was GREEN.

The damage to the oil cooler's coolant side was probably done as soon as the universal went into the degas bottle. I am sure the gelling from the mixed coolants contributed to the mess I found when I flushed the system upon installing the coolant filter. After FIFTEEN flushes following a VC-9 treatment, the distilled water came out clear.

When I changed the coolant filter the first time, there was quite a bit of debris in the filter media. At the second change (when I replaced the EGR cooler) there was still debris but much less than the first.

I would strongly encourage you to immediately get a coolant filter on your 6.0L. As you say, International uses ELC; they also use a coolant filter on their VT365. If your '04 SMB hasn't been flushed it too is likely due for a look as my own '05 was overdue. I even had the new coolant analyzed several weeks after the flush and the results showed elevated levels of solder in the coolant...so I had some advance indicators that there had been some damage from the mixed coolants. The lab thought the solder might be from the radiator instead of the EGR cooler or oil cooler so I guess I might even have another "issue" ahead of me (although the truck is much cooler now during even rugged operation).

Thanks for your note and I agree, it would seem that much of the 6.0L's undeservedly bad reputation comes from an oil cooler design that requires a superior coolant (ELC) and coolant filtration system than what the factory provided. I've learned my lesson and will change to ELC as well.

Jonathan

 

[Saline]

I have been planning on flushing soon and switching over to ELC. I have been running a coolant filter for about 15k miles now. It's amazing to see the crap that's floating around in the coolant system!

 

[howell_jd]

I was amazed at first but then I realized that the high cavitation and pressure of a large capacity coolant system will create just this sort of wear effect on a cast block. Certainly the presence of disolved solids facilitates further ablation. Keeping it clean is an ongoing job no doubt! I am certain that ELC will reduce the amount of solids but it won't change the fact that cavitation will erode metals too. Drat!

Jonathan