Sinister Diesel EGR Cooler | 2004–2007 Ford Powerstroke 6.0L
Key Features
• 50-state legal replacement EGR cooler with CARB EO# D-721
• Stainless steel internal tube design eliminates factory fin-style failure points
• Fully TIG-welded and pressure tested for long-term reliability
• Improved exhaust gas flow compared to the factory cooler
• Direct-fit replacement designed specifically for the 6.0L Powerstroke
• Compatible with stock ECM and all performance tuners
• Proven solution trusted by tens of thousands of 6.0L Powerstroke owners
• Backed by a 2-year warranty
Product Overview
Sinister Diesel has completely re-engineered the EGR cooler for the 6.0L Powerstroke to address the most common and costly failure points found in the factory design. The OEM EGR cooler relies on narrow internal cooling fins joined by brazed connections. When those brazed joints crack, coolant can be drawn into the intake manifold and combustion chamber, often leading to blown head gaskets, hydro-lock, and extremely expensive engine repairs.
The Sinister Diesel EGR Cooler replaces the restrictive fin-style core with high-flow stainless steel tubing that is fully TIG welded for superior strength and durability. This design dramatically reduces the risk of internal failure, clogging, and coolant intrusion while improving exhaust gas flow and long-term reliability.
This isn’t a theoretical upgrade — tens of thousands of satisfied 6.0L Powerstroke owners are running Sinister Diesel EGR coolers every day in work trucks, tow rigs, and daily drivers. The design has been proven over years of real-world use to deliver reliability the factory cooler simply can’t match.
Designed to match factory fitment, this EGR cooler installs as a direct replacement on 2004–2007 Ford F-250, F-350 Super Duty, and Ford Excursion models equipped with the 6.0L Powerstroke. It works seamlessly with the factory ECM and remains fully compatible with all performance tuners on the market.
Each cooler is extensively tested at Sinister Diesel’s California headquarters and is certified 50-state legal under CARB EO# D-721, giving you peace of mind whether you’re returning a truck to emissions compliance, preparing it for resale, or simply replacing a failed factory unit with a more reliable solution.
Important Fitment Note
Some early 2004 6.0L Powerstroke engines were equipped with a round-style EGR cooler instead of the later square-style design. This EGR cooler is intended for square-style applications. Please verify which EGR cooler style your vehicle is equipped with before ordering to ensure proper fitment.
What’s Included
• Sinister Diesel EGR Cooler for 2004–2007 Ford Powerstroke 6.0L
Frequently Asked Questions
Q: Is this EGR cooler 50-state legal?
A: Yes. This EGR cooler is CARB certified under EO# D-721 and is legal for use in all 50 states.
Q: Do I need to remove the intake manifold to install this EGR cooler?
A: Yes. The intake manifold does need to be removed to properly install the Sinister Diesel EGR Cooler. To make installation easier and ensure a proper seal during reassembly, we strongly recommend replacing the intake gaskets at the same time. Sinister Diesel offers a replacement intake gasket kit specifically for this job.
Q: Will this work with stock tuning or aftermarket tuners?
A: Yes. This EGR cooler is fully compatible with the factory ECM and works with all performance tuners without requiring any modifications.
Q: How is this different from the factory EGR cooler?
A: The factory cooler uses fin-style passages with brazed joints that are prone to cracking and clogging. The Sinister Diesel EGR Cooler uses stainless steel tubing with TIG welds, greatly improving durability, flow, and long-term reliability.
Q: How do I know if my truck has a round or square EGR cooler?
A: Some early 2004 models used a round-style EGR cooler, while later 2004–2007 trucks use a square-style cooler. A visual inspection of the EGR cooler or confirmation by VIN/build date is recommended before ordering. If you’re unsure, our support team can help verify fitment.
Q: What vehicles does this fit?
A: This EGR cooler fits 2004, 2005, 2006, and 2007 Ford F-250, F-350 Super Duty, and Ford Excursion models equipped with the 6.0L Powerstroke diesel engine that use the square-style EGR cooler.
