If you own a 2003-2007 Ford F-Series pickup or Econoline Van, you've probably had at least one issue related to the factory EGR (exhaust gas recirculation) system. If not, you are probably a few months away from experiencing a problem.
You see, every F-series, Super duty pickup or Econoline van equipped with the International-sourced 6.0L Power Stroke diesel has a EGR cooler in it. These EGR coolers use engine coolant to scavage BTUs from the hot exhaust gases before the turbocharger. Due to a poor interior design of theses EGR coolers, over time, cracks develop. These cracks are a direct result of high heat and pressure withing the unit.
Bulletproof Diesel, of Mesa, Arizona took notice of this problem back in 2007 and decided to build a better mouse trap.
This week, I spent three full days learning the ins and outs of the Ford 6.0L Power Stroke engine. Today, I am basically shocked at International's design of the 6.0L oil cooling and filtration system. I learned that many cost-cutting corners were employed to bring the price point down on the power plant for Ford. Items such as the use of nylon filter screens where stainless steel should have been, simply baffled me. Cheap plastic parts control the life blood of these engines, and in most every case, eventually fail, resulting in costly repairs and a low, low resale value.
I'm working on a story about keeping the potent 6.0L Power Stroke diesel engine alive. I aim to learn just how much reliable power you can expect from this engine once upgrades are made.
If you own a 6.0L Power Stroke, you're going to want to read this article.