EGR Cooler Labor - Diesel Forum

FordOD · 10-14-2009, 03:23 PM

My 6.0 has been blowing white smoke the last couple days at start up and is reduced as the truck is driven a while. The problem was diagnosed as EGR cooler failure and I was quoted 20hrs of labor at the dealer (but they are trying to be nice and charging me for 18hrs). Does this sound appropriate?

I currently have 115k miles.

FordOD · 10-14-2009, 04:13 PM

They're also replacing the oil cooler.

**Sheetrockman** · 10-14-2009, 05:58 PM

that is a high number but it is also about what they charged me when they did mine. Since then I personally did the oil cooler change and it only took me 1 day to do that so the EGR cooler should be less. At 11kk are you still in warranty and if not I would recommend deleting the EGR cooler altogether. I did and wish I had done it sooner.

930Pilot · 10-14-2009, 09:46 PM

Quote:

Originally Posted by Sheetrockman

At 11kk are you still in warranty and if not I would recommend deleting the EGR cooler altogether. I did and wish I had done it sooner.

Why? Piece of mind or is the engine running "better"?

ABrown134 · 10-14-2009, 11:06 PM

Quote:

Originally Posted by FordOD

They're also replacing the oil cooler.

I don't know the exact number of hours it took, but I picked up my truck today for the exact same thing. Only glanced at the invoice cause it made me sick to have these kind of problems with only 56k on it. The dealer tore into it Monday, diagnosed by 1100, and it was ready today about 1400.

And if they haven't given you the estimate yet, the number on the bottom of the invoice will be around 2,300. No big surprise, but even with low miles and 6 months out of the 5 year warranty, no help with the cost.

Really wish I had considered doing the delete this summer...

Aaron

Albin · 10-15-2009, 08:01 AM

A friend of mine just had this done (EGR cooler, oil cooler and degas bottle) replacement at the dealer and it cost him $2200. The EGR cooler was taken out by a clogged oil cooler. His was a 2004 with only 44k miles on it. He was out of the factory warranty but not the extended warranty. The EW wouldn't cover it due to "contaminated fluids".

He now has a Dieselsite.com coolant filter installed; should never have another EGR cooler failure again (knock on wood).

Good luck.

Al

**Sheetrockman** · 10-15-2009, 11:18 AM

I wouldn't say you won't have another EGR cooler failure. I had one replaced and in less than 2 years it went out again. Part of why I went with the delete. The delete doesn't necessarily make it run better but it is piece of mind. When it leaks water gets into the intake and then the engine lifting the heads ( expensive repair ) and then out the exhaust through the turbo ( not as expensive but still not cheap ) and the delete kit fixes that problem. If you are in a state that checks emissions you may not want to do this but I am not so I did it and drive a lot easier knowing I won't have that issue again.

Albin · 10-15-2009, 12:27 PM

Sheetrock, do you or did you have a coolant filter installed? If not, then replacing the failed EGR cooler only fixed the symptom, not the problem, IMO.

Al

FordOD · 10-15-2009, 01:13 PM

So, a couple of you are saying around $2200, but I was quoted 3100. Are these $2200 repairs at a dealer? If so, I need to call another one to quote when I pick up my truck tomorrow.

**Sheetrockman** · 10-16-2009, 08:56 AM

Yes I have since installed a coolant filter but that is not the problem with the cooler. it is a poor design and it boils the coolant causing metal fatigue in the cooler radiator thus it leaks.

Fallonpowerstroke · 10-16-2009, 10:36 AM

I didnt have the egr cooler replaced but i did have the entire front of the motor removed to replace busted oil pump/water pump housing replaced plus grenaded oil pump gears. total hours 12. my truck is a 04 with 65,000 miles. went over 5 years in Feb. Didnt even bother with dealer, went with local international mechanic. Best idea ever.

ridintall · 10-16-2009, 11:56 AM

Quote:

Originally Posted by Albin

The EW wouldn't cover it due to "contaminated fluids".

I'm curious what contaminated the fluid to begin with. Was it the failure of the oil cooler that put oil in the coolant. I find it odd that the EW wouldn't cover it due to fluid contamination. I mean it's a closed system and if it was factory coolant and still under the 100K mile change interval, than the only thing that could have contaminated it was some type of failure from inside the system which should have been covered. Maybe I'm missing something it just sounds like a lame excuse to not have it covered.

BTW, new EGR and oil cooler for my van was $4500 but that also included a new drive belt and transfer case flush ( and I called two other shops which were all within ~$150 of each other). You guys are getting off cheaper than us vanners. I have a coolant filter installed now and will be looking at making further "upgrades".

FordOD · 10-16-2009, 12:27 PM

So, does a coolant filter help protect the EGR cooler from breaking down?

bismic · 10-16-2009, 02:00 PM

Quote:

Originally Posted by Sheetrockman

Yes I have since installed a coolant filter but that is not the problem with the cooler. it is a poor design and it boils the coolant causing metal fatigue in the cooler radiator thus it leaks.

The cooler design is fine if you have enough coolant flow to it. When the oil cooler plugs up on the coolant side it reduces the coolant floe to the EGR cooler (they are in series).

For a failed EGR cooler:
The primary cause is poor coolant quality (ie solids in the coolant).
The secondary cause is a plugged oil cooler.

If you have a failed EGR cooler and you replace it and you install a coolant filter, BUT you do NOT replace the plugged oil cooler, you will be installing another EGR cooler.

teamroper60 · 10-16-2009, 02:07 PM

Quote:

Originally Posted by bismic

If you have a failed EGR cooler and you replace it and you install a coolant filter, BUT you do NOT replace the plugged oil cooler, you will be installing another EGR cooler.

I agree...