EGR cooler hose replacement - with pictures - Diesel Forum - TheDieselStop.com
Ford Diesel Forum / Powerstroke Forum
Ford Diesel Forum / Powerstroke Forum
Go Back   Diesel Forum - TheDieselStop.com > 1999-2007 Ford Super Duties > 6.0L Power Stroke Engine and Drivetrain > 6.0L Power Stroke Engine and Drivetrain FAQ

6.0L Power Stroke Engine and Drivetrain FAQ Frequently asked questions in the 6.0L Power Stroke Engine and Drivetrain forum.

TheDieselstop.com is the premier Diesel Truck Forum on the internet. Registered Users do not see the above ads.
Reply
 
LinkBack Thread Tools Display Modes
Old 10-08-2007, 03:51 PM   #1 (permalink)
Senior Member
 
Join Date: Sep 2005
Posts: 1,076
My Photos: (38)
Feedback Score: 0 reviews
EGR cooler hose replacement - with pictures

Here is how to replace the orange EGR cooler hose without removing the intake manifold or EGR cooler.

Start by identifying the leak. This leak is usually present for a short time after the engine has fully cooled down. A few drops of coolant will appear to be dripping off the lower rear corner of the right cylinder head.

Look for coolant below the orange hose

If you've got coolant here, then take out the turbo and pedestal.

Turbo and pedestal out

Drain out some coolant, so when you disconnect the EGR cooler hose you won't dump coolant everywhere.

Turn the hose so the "1" symbol is straight up
Slide the hose straight back
Have these two o-rings on hand
Note: the cover may be a bit difficult to get off. Work it side to side to keep from breaking anything. If you get medieval with it, the cover will break.

Install the two new o-rings along with your new EGR cooler hose (it will be blue) and put 'er all back together...

Beer time...

__________________
What sig?
GregH is offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Old 10-08-2007, 05:37 PM   #2 (permalink)
Senior Member
 
weasel79's Avatar
 
Join Date: Jan 2007
Location: Michigan
Posts: 990
My Photos: (2)
Feedback Score: 0 reviews
Re: EGR cooler hose replacement - with pictures

Another one for you! Ill get the first case! LOL
__________________
2003 F-250SD XLT X-Cab short box March 03 6.0L Torque shift, manual 4x4 superwinch hubs, 121,000 miles,315/75/16 BF Goodrich mud terrains, autometer boost/fuel psi/tranny temp, AFE 4" straight pipe, tire clearance and guage photos
weasel79 is offline   Reply With Quote Quick reply to this message
Old 10-10-2007, 04:57 PM   #3 (permalink)
Senior Member
 
AllOutFirefighter13's Avatar
 
Join Date: Jul 2004
Location: Good Ole Needville, TX
Posts: 937
My Photos: (4)
Feedback Score: 0 reviews
Re: EGR cooler hose replacement - with pictures

<span style="color: blue"> Greg ,

Awesome right up...you never cease to amaze me. Your contributions are a true asset to TDS!

Later, </span>
__________________
Joey

* '04 F250 XCab LWB 4X4 w/ FX4 *
* TorqShift *
* Manual 4WD *
* Carpet Delete *
* No. 2 ONLY *
* High-Idle Mod *
* Fumoto Valve *
AllOutFirefighter13 is offline   Reply With Quote Quick reply to this message
Old 10-20-2007, 08:27 PM   #4 (permalink)
Junior Member
 
Join Date: Mar 2004
Location: TX
Posts: 21
My Photos: (0)
Feedback Score: 0 reviews
Re: EGR cooler hose replacement - with pictures

Any chance you know and could post up those part numbers?

Thanks
__________________
04/04 F-350, 6.0, 6-speed, Lariat, CC LB, Silver, FX4, Recieved 2/13/04, X springs and part of mini spring pack, buckstop front bumper, AIC, guages, 285 BFG AT's, DPPI turbo back exhaust, AFE intake, UWS toolbox, weighed in at 8100 with full tank, 106,000 miles so far.
04txdiesel is offline   Reply With Quote Quick reply to this message
Old 10-24-2007, 02:16 PM   #5 (permalink)
Senior Member
 
Join Date: Dec 2005
Location: NJ
Posts: 482
My Photos: (0)
Feedback Score: 0 reviews
Re: EGR cooler hose replacement - with pictures

Greg,

How much coolant debris/grunge do you guys normally see when you remove egr and oil coolers?
__________________
'04 Excursion EB, 6.0 PS, 4X4, Magnaflow Performance exhaust, Isspro gauges (boost, pyro and tranny), Bilsteins, aFe intake, front and rear leaf spring upgrade w/ bags, 30mm rear sway bar, SCT Xcal2, Red-Head box, Jordan brake controller, Arctic Fox 29V - 20,420# GCW, Everything haulin' me, the wife, the 5 Amigos, Millie and Yogi (our 2 Berners).
Stewey is offline   Reply With Quote Quick reply to this message
Old 10-24-2007, 07:41 PM   #6 (permalink)
Senior Member
 
Join Date: Jan 2005
Location: Pickerington, Ohio
Posts: 1,088
My Photos: (14)
Feedback Score: 0 reviews
Send a message via AIM to edub32
Re: EGR cooler hose replacement - with pictures

yeah can we get some part numbers for the new hose and orings please
__________________
2001 F350 7.3 SCLB 4x4 Off-Road SRW
- DP Tuner, Tymar intake, 35" BFG Mudders on 16x10 Mickey T's, Superlift 6" lift, DiPricol 3 gauge Pillar, 4" SS DP to 5" sidepipe to 6" Chrome tip, WW, Panasonic Deck with 4xInfinity References, Overboost Elim., CCV
edub32 is offline   Reply With Quote Quick reply to this message
Old 01-21-2008, 07:58 PM   #7 (permalink)
Junior Member
 
fast72lemans's Avatar
 
Join Date: Jan 2008
Location: Scenic Mongomery County, Pa
Posts: 9
My Photos: (4)
Feedback Score: 0 reviews
I've noticed this since the temp dipped into the teens, What kind of time are you looking at to replace the hose and seals? It's funny but if I plug the block heater in, it doesn't leak.
fast72lemans is offline   Reply With Quote Quick reply to this message
Old 05-03-2008, 12:14 AM   #8 (permalink)
Senior Member
 
dsltek's Avatar
 
Join Date: May 2008
Location: The MoToRcItY
Posts: 114
My Photos: (0)
Feedback Score: 0 reviews
orange egr hose now blue....basic part #8592 dealer will knw.....the housing that hose connects to 9p456.......btw i do them all day long 20min only remove the cac tube!!!!
pbeu135@hotmail.com
dsltek is offline   Reply With Quote Quick reply to this message
Old 05-03-2008, 09:33 PM   #9 (permalink)
Junior Member
 
Join Date: Mar 2008
Posts: 4
My Photos: (0)
Feedback Score: 0 reviews
if your good you dont have to take the turbo or pedestal out
Fordjunky10 is offline   Reply With Quote Quick reply to this message
Old 05-05-2008, 04:39 PM   #10 (permalink)
Senior Member
 
dsltek's Avatar
 
Join Date: May 2008
Location: The MoToRcItY
Posts: 114
My Photos: (0)
Feedback Score: 0 reviews
oh no turbo no pedestal jst the cac tube and an arsenal of choice weapons lol
dsltek is offline   Reply With Quote Quick reply to this message
Old 12-08-2009, 04:14 PM   #11 (permalink)
Junior Member
 
Join Date: Dec 2009
Posts: 3
My Photos: (0)
Feedback Score: 0 reviews
egr cooler supply housing

Is there a trick to removing the egr supply housing. have the cover off and can move the housing with alittle help from a couple of pry bars (gently) but it doesnt want to come straight up.THX

Last edited by 357sparky; 12-08-2009 at 04:15 PM. Reason: misspelled
357sparky is offline   Reply With Quote Quick reply to this message
Old 12-08-2009, 04:35 PM   #12 (permalink)
Junior Member
 
Join Date: Dec 2009
Posts: 3
My Photos: (0)
Feedback Score: 0 reviews
never mind GOT IT
357sparky is offline   Reply With Quote Quick reply to this message
Old 12-09-2009, 06:26 PM   #13 (permalink)
Junior Member
 
Join Date: Jun 2004
Location: Florissant, Mo.
Posts: 25
My Photos: (0)
Feedback Score: 0 reviews
I had the same problem. I put the hose on the housing first before I put it back on. This worked the best for me, I could not get my fingers around the hose. I have not seen anymore fluid on below 25 DEG days.
__________________
2003 F-250 EXT. CAB 4X4, Full Bed, 6 speed
Upgrades: locking fuel cap, CYCLOPS No-Start Relay, hood light (1U5Z15702AA), new style HFCM drain plug (6E7Z9C082A), glove box light (E7DZ14413A), DIESELSITE Coolant Filter Kit, cruise control (2C3Z9A818BAB),blue coolant hose(4C4Z-8592-AA) & (3C3Z-9N693-FA,3C3Z-9 N693-EA)
toddwfli is offline   Reply With Quote Quick reply to this message
Old 12-10-2009, 07:19 PM   #14 (permalink)
Member
 
skrub67's Avatar
 
Join Date: May 2008
Location: Quantico, VA
Posts: 65
My Photos: (13)
Feedback Score: 0 reviews
Holy batman... Just spoke to my local dealer.. they want $400...I say again, $400 to replace the EGR cooler hose...I already have the hose, coolant and gaskets that go to the little housing that the hose hooks up to opposite the EGR cooler. I about hit the floor.

I think I will try this repair myself....I hope it turns out well...lol
__________________
Guns don't kill people, people kill people. Take our guns away and then the law biding folks are screwed. All the criminals will be armed.

http://img.photobucket.com/albums/v2...s/101_1455.jpg

2004 F250 with an 2003 6.0 in her, Dick Cepek Black DC1 Wheels, 315 75R BFG's, SCT X3, 4" DP, 4" exhaust w/ kitty, 5" tailpipe, 6" Fab Tech Lift, MX 6 Shocks, K&N CAI, Awesome Tunes by Eric at Innovative, DVD,135K (Nov 11)

1967 Chevy C-10 step side, 383 stroker, Holley 750, TH400 w/stall, 6/4 lowered, body shaved, gas tank relocated... and many more.

2009 Toyata Venza...the wife's...lol
skrub67 is offline   Reply With Quote Quick reply to this message
Old 12-19-2009, 12:49 AM   #15 (permalink)
Junior Member
 
Join Date: May 2007
Location: AZ
Posts: 4
My Photos: (0)
Feedback Score: 0 reviews
RE:

Quote:
Originally Posted by Fordjunky10 View Post
if your good you dont have to take the turbo or pedestal out
My hose appeared to be intact, but the cheap clamp Ford used didn't seem to be tight enough. I cut the old clamp off (without removing the turbo) with some diagonals and slid a regular hose clamp around it, snugged it up, no more leak...(did get a charley horse in my hand from contorting it to thread the hose clamp together...)
eazrider is offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Reply

  Diesel Forum - TheDieselStop.com > 1999-2007 Ford Super Duties > 6.0L Power Stroke Engine and Drivetrain > 6.0L Power Stroke Engine and Drivetrain FAQ

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Diesel Forum - TheDieselStop.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
If you do not want to register, fill this field only and the name will be used as user name for your post.
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



Wheel & Tire Center

Powered by vBadvanced CMPS v3.2.3

All times are GMT -5. The time now is 03:36 AM.



Powered by vBulletin® Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Search Engine Friendly URLs by vBSEO 3.6.0

vBulletin Optimisation provided by vB Optimise (Pro) - vBulletin Mods & Addons Copyright © 2014 DragonByte Technologies Ltd.