Welding EGR Shut. - TheDieselGarage.com
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post #1 of 15 (permalink) Old 12-07-2011, 03:40 AM Thread Starter
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Exclamation Welding EGR Shut.

I have a 2005 f250 with 170,000 miles. I pulled my EGR valve tonight and it was wet. My truck blows white smoke out of exhaust only on morning start-ups. When the motor gets hot and you shut the engine off and re-start it, there is no smoke anymore and seems to run great. I'm also experiencing some coolant loss.

Again truck runs fine after the initial morning start-up.

Now that you know the issues here is my solution. I have done some searching on this site and it seems that the EGR is a serious problem with the 6.0's.

I want to Take the EGR off and weld the ends shut. I'm Qa/Qc at a welding shop and have some excellent welders that will weld it shut for me.

For anyone that has done this before.. Please give me any advice possible and also how much work is involved to remove the EGR cooler?

I would like to remove the EGR myself and take it to my shop to have it welded and then re-install it myself.

Is there any how-to write ups on the process? Any pictures or videos?

Again I appreciate any advice that yall give me. Thanks.
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post #2 of 15 (permalink) Old 12-07-2011, 04:17 AM Thread Starter
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Unhappy

BTW how long do you think I have before I start experiencing major problems? This is my only method of transportation.
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post #3 of 15 (permalink) Old 12-07-2011, 12:36 PM
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The EGR valve being welded shut still doesn't solve the problem of a leaking EGR cooler. You should pull the cooler and weld it shut, but you will need a tuner to shut off an engine light that will pop up. Most likely you will get an engine light with what you are doing also. What you may try is go to your local Ford and ask the mechanics in the shop for an old leaking EGR cooler that you can have. Mod it and less down time.

Last edited by lenzhotrod; 12-07-2011 at 12:39 PM.
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post #4 of 15 (permalink) Old 12-07-2011, 12:44 PM
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There are lots of delete kits. Bulletproof makes a delete and a new cooler that is guaranteed and cost the same as the delete, $350, and you don't have to get a programmer to shut off the engine light.

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post #5 of 15 (permalink) Old 12-07-2011, 01:06 PM
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Egr cooler failure, which your truck shows the classic symptom of having, is nearly always a result of the engine oil cooler being clogged and restricting coolant flow into the egr cooler. The coolant flows into the oil cooler first then out to the egr cooler. The low flow of coolant into the egr cooler causes the egr cooler to overheat and crack. Highly recommend replacing the oil cooler while your in there. Turbo and intake manifold removal is required for access. As mentioned, if you weld up the ends of the egr cooler, then you will have a check engine light on, same with a egr cooler delete kit. If you have emission testing for diesel powered pickups in your area, then you may want to consider retaining the egr system, and go with a Bulletproof brand egr cooler.

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post #6 of 15 (permalink) Old 12-07-2011, 01:10 PM Thread Starter
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I'm on a budget with Christmas right around the corner so welding the EGR COOLER will be my best option right now.

Any advice on removing the cooler or how-to's?

Thanks
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post #7 of 15 (permalink) Old 12-07-2011, 01:22 PM
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NOW IS NOT THE TIME TO BE CHEAP!!!!! cap letters means I'm yelling at you!!

You need to check the delta of your ECT/EOT. There is a good chance that your oil cooler is blocked up.

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post #8 of 15 (permalink) Old 12-07-2011, 08:35 PM
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Like stated earlier your cooler is usually the symptom of a bad oil cooler. Just welding the EGR cooler is buying you time but your damage will continue unless you are one of the lucky few that only has a bad EGR cooler.
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post #9 of 15 (permalink) Old 12-08-2011, 03:03 AM
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Moisture is a sign your cracked.... welding it shut is not an option unless you re-rout coolant.

Kits are under $300 for the really high end stuff, which I recommend. You can get Chinese Take out for less.

OP above are correct, the oil cooler being jammed packed will cause a cooler to crack

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post #10 of 15 (permalink) Old 12-08-2011, 03:04 AM
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Depending on the year of your truck the delete kits have advantages for performance as well as MPG's

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