Home » 2008-2010 6.4L Ford Powerstroke F250 F350 F450 EGR Delete Kit

Compatibility: 2008–2010 Ford Super Duty F-250 / F-350 / F-450 (6.4L Powerstroke) Product: Dual EGR Cooler Delete & High-Flow Intake Elbow Performance Kit

LEGAL DISCLAIMER & COMPLIANCE

OFF-ROAD USE ONLY: This high-performance racing component is engineered exclusively for competition or sanctioned off-road use. It does not comply with federal or local emissions laws for highway operation. Installation on any vehicle registered for public roads is strictly prohibited. The end-user assumes all legal liability and risk associated with the installation and use of this product.

PHASE 1: COOLING SYSTEM & RESERVOIR REMOVAL

Step 1: Fluid Management

  1. Safety: Disconnect both negative battery terminals.

  2. System Drain: Locate the radiator drain plug on the lower driver-side corner. Drain the coolant into a clean container.

  3. Line Recovery: Remove the 3/8” coolant hose connected to the degas (overflow) bottle. Retain this hose for the final re-routing in Phase 4.

Step 2: Component Clearance

  1. Remove the upper radiator hose by releasing the wire retaining clip and pulling the hose straight out.

  2. Disconnect all remaining coolant hoses from the degas bottle and the vent line attached to the battery tray.

  3. Remove the four (4) mounting bolts to extract the battery tray and degas bottle assembly from the engine bay.

Step 3: Charge Air Cooler (CAC) Isolation Loosen the clamp on the driver-side intercooler tube and pull the tube from the rubber boot. You only need to separate the connection to create space; full removal is not required.

PHASE 2: VERTICAL & HORIZONTAL EGR COOLER EXTRACTION

Step 4: Cooler Separation

  1. Disconnect the electrical harness on top of the vertical EGR cooler.

  2. Remove the hardware securing the vertical and horizontal coolers together. Release the mounting clamps and carefully pry the flanges apart to separate the units.

Step 5: Vertical Cooler Removal Hold the intercooler tube aside to create clearance. Rotate the vertical EGR cooler as needed to release it from its bracket and lift it out of the engine bay.

Step 6: Thermostat Housing Remove the upper radiator hose from the thermostat housing.

  • Tech Tip: If your factory hose utilizes a single O-ring, it is highly recommended to upgrade to a double O-ring version during reassembly to prevent future leaks.

Step 7: Upper Mount Removal Remove the three (3) 10mm bolts and one (1) 13mm stud securing the upper EGR cooler mount. Save the 13mm stud; it is required to secure the power steering line later.

Step 8: Steering Shaft Clearance Remove the steering shaft bolt. Slide the stem upward to disconnect it from the steering box shaft.

  • WARNING: Do not rotate the steering wheel or tires while the shaft is disconnected to avoid damaging the clock spring.

Step 9: Lower Cooler Extraction

  1. Remove the dipstick tube mounting nut and release the clamps on the lower (horizontal) EGR cooler. Access via the wheel well may provide better leverage.

  2. Disconnect the coolant line from the cooler (this line is not reused and can be cut for easier removal).

  3. Remove the rear flange bolts. Access the top bolt from the engine bay and the bottom bolt from underneath the vehicle.

Step 10: Final Extraction Move the dipstick tube aside. Rotate the lower EGR cooler out of its mount and pull forward to remove. Remove the final bolt securing the coolant line to the timing cover.

PHASE 3: COMPONENT INSTALLATION & BLOCK-OFF

Step 11: Manifold & Port Sealing

  1. Install the four (4) provided M10-1.25x40mm bolts into the exhaust manifold and torque to factory specifications.

  2. Remove the factory coolant tube that ran from the vertical cooler to the engine. Install the provided block-off plugs using the factory hardware to seal the port.

Step 12: Bracket Restoration

  1. Using the provided spacer, re-install the 13mm stud saved from Step 7. Secure the power steering line to this stud.

  2. Re-install the plastic coolant tube and reconnect the steering shaft, torquing hardware to factory specifications.

  3. Re-install the battery tray and degas bottle, reconnecting all associated coolant and vent lines.

PHASE 4: INTAKE ELBOW & COOLANT RE-ROUTING

Step 13: EGR Valve Removal Remove the four (4) bolts and loosen the hose clamp on the intercooler plumbing to extract the factory EGR valve assembly.

Step 14: High-Flow Intake Elbow Installation Slide the new intake elbow tube into the intercooler boot. Secure the flange to the intake manifold using the supplied M6-1.25x25mm bolts.

Step 15: Final Coolant Re-Route Retrieve the 3/8" hose saved from Step 1. Use the provided barbed union to reconnect the coolant line running across the radiator to the degas bottle. Trim the hose to the appropriate length and secure using factory clamps.

Step 16: Final Inspection Secure the newly routed coolant line using the provided plastic routing clips. Refill the cooling system with approved Motorcraft Gold (or equivalent) coolant. Start the engine, check for leaks, and top off fluid once the thermostat opens.

POST-INSTALLATION ADVISORY

  • ECM Tuning: This hardware modification requires a compatible Race Tune (e.g., SCT, H&S) to disable EGR logic and prevent Check Engine Lights or Limp Mode.

  • Audit: Re-check the steering shaft bolt torque after the first 50 miles.