EGR Cooler-Oil Cooler-Head Studs
2003-2007 6.0L Powerstroke diesel engines definitely have a weak link with the EGR cooler and oil cooler. The 6.0L blocks are sand casted. With this being said, there are casting materials that over time break down and get stuck in the oil cooler. This causes blockages in the oil cooler which can lead to higher oil and coolant temperatures. The rising coolant temperatures and lack of coolant flow is what ultimately causes the EGR cooler failure and cause head gasket failure in extreme conditions. Here at PDA we use Bullet Proof Diesel products to ensure the vehicle gets repaired correctly the first time and will not have the same problem again. Following are a couple of different ways to repair this problems that the customer can decide.
Solution #1: Replace the stock EGR cooler with a Bullet Proof Diesel cooler and also replace the stock oil cooler with a stock oil cooler element.
Solution #2: Replace the stock EGR cooler with a Bullet Proof Diesel cooler and also upgrade the oil cooler to a Bullet Proof Diesel bypass oil cooler kit.
Solution #3: Replace the stock EGR cooler with a Bullet Proof Diesel cooler, upgrade the oil cooler to a Bullet Proof Diesel bypass oil cooler kit and replace the head studs and gaskets with ARP head studs and OEM upgrade Gaskets.