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Wednesday, June 15, 2011

Learning to Live with Your Powerstroke 6.0L EGR

One look at the picture below explains why I am not a fan of EGR systems, especially on the Powerstroke. However, ever-stricter emissions regulations pushed Ford to adopt them on its diesels, but judging by how much warranty money Ford has unloaded on failed EGR coolers, I'm guessing that the coolers are not on its list of top ten company moneymakers. The early 6.0 L Power Stroke engines have proven themselves to be unreliable. Folks have speculated that they cost Ford hundreds of millions of dollars in warranty repairs. The 2003 through early 2005 models led to many recalls and the repurchase of at least 500 trucks. I can’t find exact figures on how many EGR coolers have failed from those model years, but I would guess it in the high hundreds of thousands. Ford sold several hundred thousand 6.0Ls a year for five years both in E-series and F-series flavors. Quality improved drastically by 2006, but if your one of the luckyones who owns one of the earlier 6.0L Powerstroke there's a good chance you know, first hand, what I am talking about. Let’s take a look at the Powerstroke EGR system, what you can expect and how you might make the best of a bad situation.