Question about 2004 Ford F250

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When did Ford Make it manditory to change out Oil Cooler when replacing EGR Cooler on F-250 or warranty would be void on that EGR Cooler?

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They do this because if the oil cooler is partialy blocked up then the coolant flow into the EGR cooler will be restricted and will cause the new cooler to fail. The leading cause of EGR cooler failure is from overheating. either from lack of coolant flow or a bad EGR valve letting to much exhaust flow through the cooler.

Posted on Oct 25, 2009

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I have an 04 Ford 6.0liter diesel and my EGR cooler is bad. I heard the Ford replacement is lousy. Is it worth getting a Bulletproof brand cooler as the replacement. Should I also replace the oil cooler...


Hello, There are 2 TSB's for the EGR and Exhaust parts. They are o5e15, NHTSA-10017996 and then 18734, NHTSA-10017864.

Once you get these changes made, you may want to hang a better part on your truck. Some of the EGR parts are considered a Pollution part and have a longer, Federally required Warranty. You may decide FREE is better and it will get you a few more years of use.

If the cooler was a big problem for your Year truck, there are only the 2 TSB's issued for the EGR area. What you would have to know about Ford Parts is the last letters in the Engineering number on the part. The first run parts have either no end letter or have an A. The next modification would have a B and so on. The Selling part number is different from the Engineering part number molded or cast onto the part. So you can have an new original 2004 made part in a box that has the same Selling number as a newer 2010 made modified part. Both boxes would show the same outside numbers, but the latest configuration may solve your concerns.

This is common for most Manufacturers, and it explains why some original parts can last 10 years and the replacement only 2 years. There is no guarantee the part has not been cheapened inside the box in later years either.

I hope my solution is very helpful to you and that the TSB fixes may help you.

Apr 01, 2011 | Ford F-250 Cars & Trucks

1 Answer

Need to remove the turbocharger from truck to replace oil cooler. Am unable to get it out. It is a 2003 ford 250 superduty tubo diesel 6.0 litre


1 - Remove the turbocharger intake tube
2 - Disconnect the charge air cooler inlet pipe
3 - Remove the push pins on turbo cowl
4 - Disconnect the turbo VGT solenoid
5 - Remove the oil supply tube
6 - Using the special tool, remove the oil feed tube
7 - Remove clamp from the turbo down pipe
8 - Remove the clamp from the turbo inlet
9 - Loosen the exhaust inlet pipe-to-EGR cooler clamp
10 - Loosen the RH & LH exhaust inlet pipe-to-exhaust manifold nuts
11 - Remove the rear turbocharger mounting bolt
12 - Remove the front mounting bolts
13 - Position the turbocharger and remove the turbocharger drain tube
14 - Remove the turbocharger

If you cant do it with these instructions put down your wrench and take to a dealership for a professional to work on it

Sep 03, 2010 | 2003 Ford F250 Super Duty Crew Cab

1 Answer

F250 Lariat Diesel turbo no function sometimes and exhaust smoke white


you didnt specify if this is a 6L or 6.4L since its an 07 it could be either. If 6.0L, White smoke typically indicates a blown egr cooler and this usually damages the egr valve which may cause it to fail open allowing the coolant to enter the combustion chambers and be burnt and cause white smoke, If its a 6.4L I have seen the highside turbo bearings fail causing poor performance and seal failure resulting in oil getting into exhaust, high exhaust temps make it burn and it may appear as a whitish colored smoke depending on severity. Hopefully for you its a 6.0L becuase the 6.4L turbo r&r is a repair where we remove the entire cab from the truck. However your not much better off with 6.0L since egr cooler/oil cooler job can easily run you $1500-2000.

Jun 28, 2010 | 2007 Ford F-250 Super Duty Lariat

1 Answer

I have a 1998 Ford E350 Van and I need to find the EGR Valve for replacement. Can anyone direct me to a Free Site to find the location?? Thanks Dave


the egr valve is onthe passenger side if you replace it do the oil cooler to if 7.3
if 6.0 the cooler is behind the tobro close too fire wall chance oil cooler to

Jan 24, 2010 | 2007 Ford E-350 Super Duty Length XLT

1 Answer

Common problem on 04 Ford Excrusion the oil cooler goes bad?


both system are week
in my case with 26 units
24 egr cooler some under warranty
2 oil cooler
you can judge by these numbers

Oct 20, 2009 | 2004 Ford Excursion

1 Answer

Egr cooler repalced to get us passed warranty - oil cooler was not replaced prior to 160k warranty exipred- on vacation 2000kms away (only 11000kms after egr cooler fixed) from home towing a trailer...


If the dealer put an egr cooler on and didnt replace oil cooler, it can blow out egr cooler again , restriced oil cooler causes egr cooler to blow out , which in turn can cause overheat and blown headgasket also, if you are seeing white smoke now it is possible for the egr to be blown out again as wel as the oil ooler and/or headgasket

Aug 03, 2009 | 2005 Ford F 250 Super Duty

1 Answer

Egr cooler


They should have replaced it right then. They know that it should be replaced if the EGR valve itself goes bad. They are trained in this and know what they are supposed to do. Tell them if they do not repair it right like they should hae 3 months ago you will go to the BBB and so on to get things right..

Apr 15, 2009 | 1999 Ford F250 Regular Cab

1 Answer

6l diesel


It does sound like an engine oil cooler failure. The cooler on this is the big lump of metal under the oil filter housing. It fits down into the block and has several hoses and sensors. The normal way to check for a leak is to pull it out and pressure test it. You may however be able to drain your coolant, then look for a short piece of hose between your oil cooler and EGR cooler. This hose will twist about 90Deg and then you can slide it back toward the EGR cooler. Make sure you have plenty of engine oil and start the engine with this hose off. If you have a bad enough oil leak the oil may be pumped out here. This may also be a craked head or a front cover problem, but most of the time those will put coolant in the oil.

Nov 10, 2008 | 2005 Ford F 250 Super Duty

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