EGR Delete + Oil Cooler + Intake Gasket Bundle for 6.0L Powerstroke Ford
6.0L Powerstroke Complete Reliability Bundle Front View
6.0L Powerstroke EGR Delete Bundle Installation Kit
6.0L Powerstroke Bundle Included Parts
EGR Performance 6.0L Powerstroke Complete Repair Bundle
EGR Delete + Oil Cooler + Intake Gasket Bundle for 6.0L Powerstroke Ford
6.0L Powerstroke Complete Reliability Bundle Front View
6.0L Powerstroke EGR Delete Bundle Installation Kit
6.0L Powerstroke Bundle Included Parts
EGR Performance 6.0L Powerstroke Complete Repair Bundle

6.0L Powerstroke EGR Delete + Oil Cooler + Intake Gasket Complete Bundle (2003-2007)

$152.90
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Details

6.0L Powerstroke Complete Reliability Repair Bundle

 
Solve the three most catastrophic failure points of the 2003-2007 Ford 6.0L Powerstroke engine with this all-in-one bundle. Designed to eliminate coolant leaks, overheating, carbon buildup and power loss in a single installation, saving you time, money and costly engine damage down the line.
 
This professionally matched kit combines our best-selling EGR delete kit, upgraded cast iron oil cooler and OEM-spec intake manifold gasket set — everything you need to permanently fix the factory design flaws that plague 6.0L Powerstroke trucks.
 

Why This 3-In-1 Bundle Is Non-Negotiable For 6.0L Owners

 
The 6.0L Powerstroke's biggest weaknesses are interconnected:
 
  • A failing oil cooler causes coolant contamination, which destroys the EGR cooler
  • A leaking EGR cooler leads to overheating and head gasket failure
  • A worn intake manifold gasket allows air leaks and oil-to-coolant mixing
 
Replacing only one component means you'll be back in the shop in 6-12 months. This bundle addresses all three issues at once, extending your engine's lifespan by 100,000+ miles.
 

What's Included In Your Bundle

Product Core Features Individual Price
6.0L EGR Delete Kit 304 stainless steel cooler plate, billet aluminum block-off plate, high-temp silicone hose, full hardware $59.99
Upgraded Oil Cooler Kit Cast iron construction, 100% leak-tested, includes all gaskets & seals, OEM replacement $79.88
Intake Manifold Gasket Set OEM-spec rubber material, precision fit, prevents air/oil/coolant leaks $36.70

Vehicle Fitment

Make/Model Year Range Engine
Ford F-250 Super Duty 2003-2007 6.0L V8 Powerstroke Diesel
Ford F-350 Super Duty 2003-2007 6.0L V8 Powerstroke Diesel
Ford F-450 Super Duty 2003-2007 6.0L V8 Powerstroke Diesel
Ford F-550 Super Duty 2003-2007 6.0L V8 Powerstroke Diesel
Ford Excursion 2003-2005 6.0L V8 Powerstroke Diesel
Ford E-350 Super Duty 2004-2010 6.0L V8 Powerstroke Diesel
Ford E-450 Super Duty 2004-2010 6.0L V8 Powerstroke Diesel

 
Shipping Details

Ontario CA / Springdale OH / Newark NJ

*Based on your shipping address, we'll pick the closest warehouse to ship from. Since some product isn't stored in the same warehouse, you might get several packages.
Package List

Complete Package Contents
Delivery Time

2-5 working days inland in the United States.

Product details

SEO Introduction

EGR Delete + Oil Cooler + Intake Gasket Complete Bundle is the ultimate reliability solution for 2003-2007 Ford F250/F350 trucks equipped with the 6.0L Powerstroke diesel engine. This professionally matched kit addresses the three most catastrophic factory design flaws in a single installation, saving you thousands in future engine repairs and downtime. Keep reading to learn how this bundle will transform your truck's performance and longevity.



Product Overview

This all-in-one bundle combines our best-selling 6.0L Powerstroke EGR delete kit, upgraded cast iron oil cooler, and OEM-spec intake manifold gasket set. It permanently eliminates coolant leaks, chronic overheating, carbon buildup, and power loss that plague stock 6.0L engines. Every component is precision-engineered to fit factory mounting points with no modification required. This single installation prevents the domino effect of failures that commonly destroy 6.0L Powerstroke engines.

Ideal For

  • Towing and Hauling: Lowers exhaust gas temperatures (EGTs) by 150-200°F for safer, more reliable towing under heavy loads
  • Daily Driving: Eliminates unexpected breakdowns and restores smooth, consistent power delivery
  • Off-Road Use: Improves engine durability in extreme off-road conditions where stock components often fail
  • Commercial Vehicles: Reduces maintenance costs and vehicle downtime for work trucks and fleet vehicles
  • Engine Performance Upgrades: Serves as the essential foundation for any further intake, exhaust, or tuning modifications
  • Long-Term Vehicle Ownership: Extends engine lifespan by 100,000+ miles and prevents costly head gasket failures

Core Advantages

  • Eliminates Catastrophic Failures: Removes faulty EGR system, upgrades oil cooler and intake seals to prevent coolant contamination and engine destruction
  • Increased Horsepower and Torque: Improves airflow and combustion efficiency for 15-25 HP gain and sharper throttle response
  • Reduced Engine Temperature: Maintains optimal oil and coolant temperatures even under maximum load conditions
  • Extended Engine Life: Prevents carbon buildup and oil degradation, protecting critical internal components
  • Direct Bolt-On Installation: Fits all factory mounting points with no cutting, welding, or modification required
  • All-In-One Complete Kit: Includes every part needed for full installation, no additional purchases necessary

Technical Specifications

  • Material: 304 Stainless Steel, Billet Aluminum, Cast Iron, High-Temperature Silicone, OEM-Spec Rubber
  • Finish: CNC Machined, Corrosion-Resistant Coating
  • Weight: 28 lbs (total package weight)
  • Dimensions: 24" x 18" x 12"
  • Warranty: 1 Year Limited Warranty against manufacturing defects

Why Choose EGR Performance

  • Premium Quality Materials: We use only industrial-grade 304 stainless steel and billet aluminum for maximum durability
  • Precision Engineering: All components are CNC machined to exact OEM specifications for perfect fitment
  • Rigorous Testing: Every part is 100% leak tested and pressure tested to ensure reliable performance under extreme conditions
  • Dedicated Customer Support: Email us at service@egrperformance.com for fast technical assistance
  • Fast Shipping from USA Warehouses: Ships within 24 hours from Ontario CA, Springdale OH or Newark NJ
  • 1 Year Limited Warranty: Comprehensive coverage for all manufacturing defects

Troubleshooting and Problem Solving

Common Issues After Installation

  • Check Engine Light
  • Rough Idle
  • Reduced Power
  • Coolant Leaks
  • Oil Leaks

Error Code Solutions

  • P0401: Insufficient EGR Flow - This is normal after EGR delete. A compatible tuner is required to clear this code permanently.
  • P0402: Excessive EGR Flow - Verify EGR block-off plate is properly installed and sealed.
  • P0128: Coolant Thermostat Malfunction - Check coolant level and thermostat operation. Replace thermostat if necessary.

How to Reset Check Engine Light After Installation

  1. Connect an OBD-II scanner to your vehicle's diagnostic port
  2. Turn the ignition to the "On" position without starting the engine
  3. Select "Clear Codes" on the scanner
  4. Start the engine and verify the light is off

What to Do If Your Vehicle Loses Power After Installation

  • Check all vacuum lines and connections for leaks
  • Verify intake manifold bolts are torqued to factory specifications
  • Ensure EGR delete plates are properly sealed
  • Check for clogged fuel injectors or fuel filter
  • Contact a professional diesel mechanic for further diagnosis

Long-Term Maintenance Tips

  • Regular Inspection: Every 5,000-10,000 miles, inspect all connections for leaks and loose hardware
  • Routine Maintenance: Change engine oil and filter every 5,000 miles, flush cooling system every 2 years
  • Wear Parts Replacement: Replace high-temperature silicone hose every 50,000 miles
  • Hardware Check: Every 15,000 miles, tighten all bolts and clamps to factory torque specifications
  • Warranty Reminder: Following these maintenance guidelines will keep your 1 Year Limited Warranty valid

Vehicle Fitment

This EGR Delete + Oil Cooler + Intake Gasket Complete Bundle is designed for all 2003-2007 Ford F-250/F-350/F-450/F-550 Super Duty, 2003-2005 Ford Excursion, and 2004-2010 Ford E-350/E-450 Super Duty models equipped with the 6.0L V8 Powerstroke diesel engine. It fits both 2WD and 4WD configurations.

This kit is not compatible with gasoline engines, California emissions-compliant vehicles, or models equipped with automatic transmission only. For 100% fitment confirmation, please send your VIN number to service@egrperformance.com.



  1. Dispatch Time: Orders will be shipped within 24 hours after successful payment.
  2. Delivery Time: 2-5 business days after dispatch (delivery speed depends on proximity to warehouse location).
  3. Return Window:7 days for unsatisfactory items45 days for quality-related issues
  4. Refund Processing: Refunds will be processed back to your original payment method within 2-4 business days after receiving the automated refund confirmation email (subject to bank verification).

What is an EGR Delete + Oil Cooler + Intake Gasket Bundle?

This is a complete 3-in-1 repair kit that addresses the three most common failure points of the 6.0L Powerstroke engine. It includes everything needed to remove the faulty EGR system, replace the problematic stock oil cooler, and install a new intake manifold gasket in a single installation.

How does this bundle work?

The EGR delete removes the failure-prone exhaust gas recirculation system, the upgraded oil cooler provides better cooling performance than the stock unit, and the new intake gasket ensures a proper seal. Together, they eliminate coolant contamination, overheating, and power loss.

What are the benefits of this bundle?

The main benefits include increased horsepower and torque, lower engine temperatures, improved fuel efficiency, extended engine life, and elimination of costly future repairs. It also provides peace of mind by preventing the domino effect of failures common in 6.0L engines.

Will this bundle void my warranty?

Modifying emissions systems may void your vehicle's manufacturer warranty. However, our components are covered by our own 1-year limited warranty against manufacturing defects. Consult your dealer for specific warranty information.

Is this bundle legal in my state?

The EGR delete kit included in this bundle is for off-road and competition use only. Disabling emissions systems violates federal law in the United States. Check your local and state regulations before installation.

Do I need a tuner for this bundle?

Yes, a compatible tuner is required to turn off the EGR-related check engine light and optimize engine performance after installation. We recommend pairing this bundle with our MiniMaxx V1 Tuner for best results.

How much horsepower does this bundle add?

Most owners can expect a gain of 15-25 horsepower and 30-40 lb-ft of torque after installation. Results may vary depending on your vehicle's condition and any additional modifications.

How much MPG gain can I expect from this bundle?

You can expect a 1-3 MPG improvement in fuel economy, especially during highway driving and towing. This is due to improved combustion efficiency and reduced engine load.

How long does it take to install this bundle?

Professional installation typically takes 6-8 hours. DIY installation may take longer depending on your experience level and available tools.

Can I install this bundle myself?

While it is possible to install this bundle yourself with basic mechanical skills, professional installation is highly recommended. Improper installation can lead to coolant leaks, engine damage, and other serious issues.

How often should I maintain this bundle?

We recommend inspecting all components every 5,000-10,000 miles. Follow the long-term maintenance tips outlined above to ensure maximum performance and longevity.

Will this bundle fit my 2005 Ford F-250 6.0L Powerstroke?

Yes, this bundle is compatible with all 2003-2007 Ford F-250 Super Duty models equipped with the 6.0L Powerstroke diesel engine. For 100% fitment confirmation, please send your VIN number to service@egrperformance.com.

What is the warranty on this bundle?

All components in this bundle are covered by a 1-year limited warranty against manufacturing defects. This warranty does not cover damage caused by improper installation, misuse, or neglect.

Do you offer technical support?

Yes, we offer dedicated technical support via email at service@egrperformance.com. Our team of diesel experts is available to answer any questions you may have before, during, or after installation.

How long does shipping take?

Orders are processed within 24 hours of payment confirmation. Shipping within the continental United States typically takes 2-5 business days, depending on your location.

Can I return this bundle if it doesn't fit?

Yes, we offer a 7-day return policy for unsatisfactory items and a 45-day return policy for quality-related issues. All returns must be in new, unused condition with original packaging.



Installation Information

Installation Difficulty Level

Moderate

Estimated Installation Time

6-8 hours

Required Tools

  • Socket Set (1/4", 3/8", 1/2" drive)
  • Torque Wrench
  • Screwdrivers (Flathead and Phillips)
  • Pliers
  • Drain Pan
  • Coolant Funnel
  • Engine Hoist (optional, for easier intake manifold removal)

Step-by-Step Installation Overview

  1. Drain engine coolant and engine oil completely
  2. Remove factory EGR cooler, oil cooler, and intake manifold assembly
  3. Install new upgraded oil cooler with included gaskets and seals
  4. Install EGR delete kit components and new intake manifold gasket
  5. Refill all fluids, check for leaks, and reset engine computer

Important Note: No printed installation instructions are included. Professional installation is highly recommended. If you need technical support, please contact us at service@egrperformance.com.