EGR Cooler Full Replacement Kit for Powerstroke 6.0L 2004.5-07

In stock

Put an end to your EGR Cooler headaches

Customers in heavy smog tested counties have been asking for it and here it is. A Sinister Replacement EGR Cooler looks and fits like stock but without all the factory EGR cooler problems. This kit contains everything needed from gasket to valve.

This kit does not work on a 2003 Powerstroke, but there is a different kit for that year.

NOTE: A $25 Core Charge is included in the price and will be refunded upon receipt of the old core.

Better Inside and Out

The factory honeycomb material has been removed from inside the cooler and replaced with a series of stainless steel tubes. The tubes allow the exhaust gas to flow more freely and faster eliminating a chance of clogging. The Sinister Replacement EGR Cooler is TIG welded and every cooler goes through a series of pressure tests to ensure you're getting a leak proof cooler.


  • This kit does not Require Complete Removal of Intake Manifold saving hours of install time
  • Direct Replacement of existing EGR Cooler
  • Works great on vehicles in heavily smog tested counties
  • Pressure Tested TIG Welds Guaranteed not to Leak
  • Includes detailed Installation Instructions
  • Factory honeycomb is replaced with bigger stainless steel tubing which allows for better exhaust gas flow into manifold
  • Will not throw a Check Engine Light on any year 6.0 Powerstroke

Kit Includes

  • Sinister Replacement EGR Cooler
  • Ford EGR valve
  • Intake gaskets
  • Turbo bolt & o-ring kit
  • Connector hose
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