Welding EGR Shut.

MonsterLugz · 12-07-2011, 03:40 AM

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.

MonsterLugz · 12-07-2011, 04:17 AM

BTW how long do you think I have before I start experiencing major problems? This is my only method of transportation.

lenzhotrod · 12-07-2011, 12:36 PM

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.

Golddigger · 12-07-2011, 12:44 PM

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.

harry6.0 · 12-07-2011, 01:06 PM

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.

Harry

MonsterLugz · 12-07-2011, 01:10 PM

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

lilpooh · 12-07-2011, 01:22 PM

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.

lenzhotrod · 12-07-2011, 08:35 PM

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.

**JacktheBear3** · 12-08-2011, 03:03 AM

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

**JacktheBear3** · 12-08-2011, 03:04 AM

Depending on the year of your truck the delete kits have advantages for performance as well as MPG's

12-07-2011, 03:40 AM	#1
MonsterLugz Junior Member Join Date: Dec 2011 Posts: 3 Points: 425 Thanks: 1 Thanked 0 Times in 0 Posts	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.

12-07-2011, 12:36 PM	#3
lenzhotrod Junior Member Join Date: Dec 2010 Posts: 586 Points: 21,695 Thanks: 32 Thanked 74 Times in 64 Posts	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.

12-07-2011, 12:44 PM	#4
Golddigger Member Join Date: Dec 2011 Location: Utah Posts: 239 Points: 12,582 Thanks: 11 Thanked 24 Times in 23 Posts	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. __________________ 2002 F-350 CC, Shortbed, 4X4, 7.3, EBV brake, 4" dual exhaust, TS performance 6 pos, Banks Big Head, built 4R100 w/triple disc torque conv, Shift kit, 35's, 139K, B&W Hitch and 5th wheel companion, Superlift Air Bags 35 x 12.50 x 17 BFG KM2: The veiws expressed are purely opinion. I in no way take responsibility for any actions or damage as a result of trying this at home. Local 3 OPERATORS UNION 1993 Int 4700 dt360, 6 speed, service truck, 6K crane, miller 302, hyd air compressor 273K

12-07-2011, 01:06 PM	#5
harry6.0 Senior Member Join Date: Dec 2008 Location: Spokane WA. area Posts: 2,255 Points: 48,654 Thanks: 751 Thanked 565 Times in 446 Posts	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. Harry __________________ Jan 03' built 6.0/F250cc4wd trqsft/SCT-tuned by KEM-Performance/Garrett Powermax vg-turbo/blue spring mod/gauges=egt+boost+fuel+SG2/exhaust/airaid intake/DR 4.5 lift/dual bilsteins/315's/greasable ball joints/powerstop/smittybuilt/kc lights/high idle mod/roll-n-lock/T5-Rotella 10w30 with (Archoil AR9100 in the oil) and (AR6200 in the fuel)http://www.archoilspokane.com/

12-07-2011, 01:22 PM	#7
lilpooh Member Join Date: Dec 2008 Location: Sassamansville PA Posts: 1,661 Points: 35,938 Thanks: 240 Thanked 258 Times in 226 Posts	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. __________________ 2004 F350 CC DRW King Ranch X-3 tunes by DJ,QT,GH,ID,Gyphon FICM tuner,head studs,II Stage 1turbo,ATS coolant recirc lines,Swamp's 48v ficm,coolant filter,Snow Perf stage II,EGR delete,AD2,4" turbo back straight pipe,K&N intake,Quad "A" pillar autometer gauges,Suncoast Tri Disk Conv.,Billet input shaft,Suncoast superduty rebuild kit,Trans-go shift kit,Mag-Hytec trans pan,CFM+ elbow,ccv mod,15K reese 5er,17" LCD TV/DVD,Cobra 29 Nitewatch CB Thanks to:JASONS REPAIR AND PERFORMANCE-TELFORD,PA. "Are diesel pickups hot rods? Yes,they are-perhaps the most versatile hot rods ever made"---Diesel Power Magazine

12-07-2011, 04:17 AM	#2
MonsterLugz Junior Member Threadstarter Join Date: Dec 2011 Posts: 3 Points: 425 Thanks: 1 Thanked 0 Times in 0 Posts	BTW how long do you think I have before I start experiencing major problems? This is my only method of transportation.

12-07-2011, 01:10 PM	#6
MonsterLugz Junior Member Threadstarter Join Date: Dec 2011 Posts: 3 Points: 425 Thanks: 1 Thanked 0 Times in 0 Posts	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

12-07-2011, 08:35 PM	#8
lenzhotrod Junior Member Join Date: Dec 2010 Posts: 586 Points: 21,695 Thanks: 32 Thanked 74 Times in 64 Posts	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.

12-08-2011, 03:03 AM	#9
JacktheBear3 Supporting Vendor Join Date: Jan 2007 Location: Northeast Ohio Posts: 174 Points: 22,757 Thanks: 5 Thanked 27 Times in 17 Posts	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 __________________

12-08-2011, 03:04 AM	#10
JacktheBear3 Supporting Vendor Join Date: Jan 2007 Location: Northeast Ohio Posts: 174 Points: 22,757 Thanks: 5 Thanked 27 Times in 17 Posts	Depending on the year of your truck the delete kits have advantages for performance as well as MPG's __________________

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