Engineered specifically for late 2004.5 through 2007 Ford F-250, F-350, F-450, F-550 Super Duty, Excursion, and 2004–2010 E-Series Vans equipped with the 6.0L Powerstroke diesel engine utilizing the square-style EGR cooler configuration (production build dates after September 22, 2003), the Bullet Proof Diesel Square EGR Cooler with H-Core Technology (NT-EGRC-2_H-Core) represents the pinnacle of emissions cooler engineering. Factory OE square coolers feature rigid brazed joints and restrictive internal honeycomb matrices that frequently rupture under extreme thermal cycling and restricted coolant flow, leading to coolant loss, white exhaust smoke, and catastrophic engine hydrolock.

Bullet Proof Diesel solves this structural flaw with their revolutionary H-Core design. Utilizing internally braided, flexible tubing that moves and flexes with extreme thermal expansion, the H-Core architecture virtually eliminates internal tube cracking over long-term heavy-duty use. This flexible design also allows for increased internal tubing density, which significantly enhances heat transfer and delivers cooler exhaust gas temperatures. Backed by a lifetime parts-only warranty, this direct-fit replacement ensures ultimate reliability for demanding street, towing, and commercial applications.

Key Features & Benefits

• Proprietary H-Core Technology: Internally braided and flexible tubing absorbs extreme thermal expansion cycles, virtually eliminating internal tube cracking.
• Increased Tubing Density: Maximizes internal surface area to boost heat transfer efficiency, lowering exhaust gas temperatures before recirculation.
• Heavy-Duty TIG-Welded Construction: Built with robust stainless steel components and fully welded seams to withstand high boost and exhaust pressures.
• Lifetime Parts Warranty: Backed by Bullet Proof Diesel’s industry-leading lifetime parts-only warranty coverage.
• Direct Bolt-In Replacement: Precision-built to match factory mounting points on late square-cooler setups without requiring custom ECU tuning.

Technical Specifications

• Manufacturer Part Number / SKU: NT-EGRC-2_H-Core / bpdNT-EGRC-2 (Bullet Proof Diesel)
• CARB Executive Order Number: E.O. D-730-1 (50-State Legal)
• OE / Superseded Interchange Numbers: Ford 4C3Z-9P456-AC, 4C3Z9P456AC, 4C3Z-9P456-AJ; International 1845145C97
• Truck Platform: Late 2004–2007 Ford Super Duty F-250, F-350, F-450, F-550, Excursion & E-Series Vans
• Engine Platform: 6.0L 32-Valve Powerstroke V8 Diesel / Navistar VT365 (Square Cooler Layout)
• Cooler Type: Square-Tube H-Core Design (Production Build Date After 09/22/2003)
• Core Requirement: None (Brand New Unit - No Core Return Required)
• Warranty: Bullet Proof Diesel Lifetime Parts-Only Warranty

Vehicle Fitment & Installation Notes

• Late 2004–2007 Ford F-250 / F-350 / F-450 / F-550 Super Duty – 6.0L Powerstroke Diesel (Built after 9/22/2003)
• Late 2004–2005 Ford Excursion – 6.0L Powerstroke Diesel
• 2004–2010 Ford E-350 / E-450 Super Duty Van – 6.0L Powerstroke Diesel
• Fits Model Years: Late 2004, 2005, 2006, 2007 (Plus E-Series commercial vans through 2010)
• Fitment Notice: Designed strictly for late 2004.5–2007 models equipped with the square EGR cooler. Does not fit early 2003 to mid-2004 trucks utilizing the round-style cooler layout. Verify your truck's physical cooler shape and engine build date before ordering. Gaskets and mounting hardware are sold separately.
• Installation Tip: Completely drain the engine coolant system, remove the intake manifold and up-pipe carefully, and inspect the engine oil cooler for restrictions. A clogged oil cooler is the primary root cause of repeat EGR cooler failures on the 6.0L platform and should be replaced simultaneously.