Sinister Diesel Complete Solution® Kit with Blue EGR Cooler 20MM Headgaskets
Fits 2004–2007 Ford F-250 / F-350 / F-450 / F-550 Super Duty and 2004–2005 Ford Excursion 6.0L Powerstroke
Key Features
• Eliminates Common 6.0L Failures
– Addresses head gasket, EGR cooler, and oil cooler issues permanently.
• Upgraded Sinister Blue EGR Cooler
– Features a durable internal tube design that outperforms factory-style coolers.
• Heavy-Duty Oil Cooler
– Improves oil flow and cooling efficiency for long-term reliability.
• ARP Head Studs
– Prevents head gasket failure with superior clamping force under high load.
• Complete Installation Package
– Includes all factory Ford gaskets, turbo hardware, and O-rings for a seamless install.
• Trusted Components
– Built with proven parts from the most respected names in diesel performance.
Product Overview
The Sinister Diesel Complete Solution® Kit with Blue EGR Cooler is the definitive fix for the 6.0L Powerstroke’s most common problems. Designed to eliminate failure-prone factory components, this all-in-one package restores reliability, improves performance, and extends engine life.
At the core of this kit is the Sinister Diesel Blue EGR Cooler, featuring an advanced internal tube design that provides unmatched cooling and durability compared to the stock fin-style cooler. Combined with a heavy-duty oil cooler, this setup ensures optimal oil temperatures and dependable performance under towing, hauling, or tuned conditions.
To eliminate the factory head bolt issue, the kit includes ARP Head Studs that deliver unbeatable clamping strength to prevent blown gaskets and loss of compression. Every gasket, seal, and hardware piece is included—no more piecing together parts from multiple sources.
What’s Included
• Sinister Diesel Blue EGR Cooler (Square Style, SD-EGRC-6.0-04)
• Upgraded Oil Cooler
• Updated Oil Cooler Screen
• Oil Cooler Gasket Kit
• ARP Head Studs with Lubricant
• 20mm Black Diamond Head Gaskets
• Factory Ford Intake Gasket
• Factory Ford Turbo Hardware & O-Ring Kit
Head Gasket Fitment Note
2003–early 2006 6.0L Powerstroke engines used 18mm dowel head gaskets. Builds after January 2006 and all 2007 models use 20mm dowel pins included in this kit. Some early engines may have been updated—verify dowel size before ordering. For 18mm applications, use our 18MM Complete Solution Kit
Why Choose the Sinister Diesel Complete Solution® Kit
Since 2009, Sinister Diesel has been the trusted source for Powerstroke reliability upgrades. Each Complete Solution® Kit is engineered and tested to solve real-world 6.0L issues, using only premium components for unmatched performance and durability. When you choose Sinister Diesel, you’re not just repairing your truck—you’re upgrading it for the long haul.
