Ford Powerstroke 2003 to 2007 (F250/F350/F450/F550)

[Rex in OTZ]

Have you encounterd the EGR mess from Hell?
I have been dealing with this issue twice in last 3 years.
 
Common problem of Ford Powerstroke 6.0L engines They either have or will develope EGR problems, the coolers and valves go bad sporadically.
Excessive heat passing through the EGR cooler can cause it to crack and fill your engine with harmful coolant resulting in catastrophic engine failure.
 there are companies that manufacture a "EGR Delete Kit" that solves the power stroke porblem, in the end the best fix was to remove the EGR and fit this kit in its stead.
 
http://performancemachinemfg.com/c-235230-ford-6-0l-powerstroke-03-07-egr-delete-kits.html
 
A kit is also available for the Dodge 2500/3500 trucks (2007 to 2011)
 
Matt Henderson of Performance Machine & Mfg quotes
"Unlike other kits on the markit This kit comes with all the related parts and gastkets & o-rings to do the job"
"Trucks still pass the smog test without the cooler, you can expect a 1.5mpg increase in efficiency"
"If you add the Tuner you a can get as much as 4 to 5 more miles per gallon"
http://performancemachinemfg.com/

[Larry L]

You need to get the EGR delete kit, it makes a difference in overall performance of the engine. You'll find at part throttle the turbo will spool up quicker and lag time goes to zero. Unfortunately you probably should remove the intake manifold and have it cleaned. They build a huge amount of deposits in the intake from the EGR and cause restriction of air passing thru it. If you've noticed a fall in fuel mileage since new, this is the most likely cause. The exhaust gas temp will also fall which makes for longer turbo life and coking at the turbo goes away. The delete kit is more than worth while.

[Sourdough]

I wish I had heard about that ERG night mare sooner.  last year I was on a trip and the Turbo Intercooler started leaking into the ERG valve.  Warped both heads.  Cost me $10, K to have the engine rebuilt.  They totally did away with all the emissions equipment.  Mileage stayed the same.