BD Diesel 1090202 Heavy Duty EGR Cooler for 6.0L Power Stroke Ford 2004-2007

The BD Diesel 1090202 is a heavy-duty replacement EGR cooler designed for 2004-2007 Ford 6.0L Power Stroke diesel engines in pickups and vans produced after September 22, 2003. This cooler addresses the critical failure issues common with OEM EGR coolers that use weak brazed joints prone to cracking and coolant leaks.

Superior Construction:

• TIG welded 304L stainless steel tubes (0.375" O.D. × 0.048" wall thickness) replace failure-prone OEM cores
• Integrated water deflectors increase coolant turbulence for improved heat dissipation
• Pressure tested to ensure leak-free operation
• Includes O-ring, threaded insert, and 1900204 gasket set for complete installation

Prevents Catastrophic Engine Damage: OEM EGR cooler failures allow coolant to enter the cylinders, causing hydrolock conditions that can destroy your engine. BD's heavy-duty design eliminates this risk with robust TIG-welded construction that won't fail at the joints.

Installation & Compliance: Professional installation recommended (approximately 3 hours). This is a direct replacement part that requires no performance tuner and will not trigger check engine lights. Legal for sale and use in all 50 states including California—no EO number required as it's classified as a replacement emissions component.

Warranty: Backed by BD Diesel's 5-year/unlimited mile limited warranty on parts, giving you long-term confidence in this critical cooling system component.

Compatibility Note: Designed specifically for Ford 6.0L Power Stroke engines with square tube EGR coolers built after September 22, 2003.