From what I've seen, any complete delete kit is going to require a serious tear down, including the intake. How else are you going to get the egr cooler out? Now...if you want to do a partial kit and keep the heat out of the cooler, you could get a bypass pipe. Basically you replace the passenger side up pipe with a straight pipe and put a cover on the intake side of the cooler. If you leave the EGR plugged in, at least on an 04, you won't get a CEL. The Scangauge won't see any codes either but that doesn't mean they're not there. Most likely some kind of "insufficient flow" code to the EGR is being thrown, but who cares, that's why you put the pipe in, right?
I would expect spiking of the coolant temps to diminish as well every time you floor it and no flash boiling of the coolant since no more exhaust gases are going into the EGR cooler. Hopefully with no(less) heat going in there it won't rupture and dump coolant into your intake. I know it's not a true EGR delete, but it's a lot cheaper, easier to do and may go along way to reducing or eliminating failure of the cooler.
When my oil cooler failed, they replaced the EGR cooler as well. I was ready to go for the complete delete kit, but it was already torn down at the dealership and they wouldn't do it so all the OEM parts went back in.
As far as the cat delete pipe, last I checked, eBay had a bunch for the 6.0. I would measure your pipe and see if one of these would fit. I think they were like $50. From what I've read, it doesn't seem to make much of a difference so now I'm looking at a complete turbo back kit for the pickups that I'll have a shop mod to fit my van.
2004 6.0 E350 Quigley 4x4 w/ Sportsmobile Conversion.
285/75R16 BFG AT/KO. 3.73 Gears.
Dieselsite Coolant Filter.
Aluminess Front/Rear Bumpers.
125W Solar Panel.
Sportsmobile Trailer on 285/75R16 BFG AT/KO tires w/ dual deep cycle marine batteries, water pump, 10 gal water storage, air compressor, storage box & 15W Solar Panel.
SnowMan Mod / Door Seal Mod
"Blue Spring" Upgrade
Last edited by ridintall; 03-16-2011 at 03:31 PM.