Engineered specifically to support EGR cooler servicing on late 2004 through 2007 Ford F-250, F-350, F-450, F-550 Super Duty and Excursion trucks equipped with the 6.0L Powerstroke diesel engine (square cooler configuration), the aFe BladeRunner EGR Cooler Gasket Kit (46-90075) provides professional-grade sealing components. Reusing flattened or heat-degraded factory gaskets during an EGR cooler replacement or maintenance procedure frequently leads to persistent exhaust gas leaks, under-hood soot blow-by, and coolant loss.

Designed specifically to match aFe's high-flow BladeRunner EGR cooler architecture as well as factory replacement units, this kit includes precision-molded interface gaskets and high-temperature seals. Each component is manufactured from robust materials formulated to endure extreme exhaust temperatures and continuous thermal expansion without shrinking or blowing out.

Key Features & Benefits

• Complete System Sealing: Includes all required interface gaskets and seals needed when servicing or replacing square-style EGR coolers.
• High-Temperature Construction: Formulated to withstand intense exhaust gas heat and chemical exposure from engine coolants.
• Prevents Soot Blow-By & Exhaust Leaks: Secures up-pipe, intake, and cooler flanges tightly to eliminate whistling under boost and exhaust odors.
• Precision OE & Aftermarket Fit: Tailored for seamless installation with aFe BladeRunner coolers and factory mounting locations.
• Reliable Maintenance Insurance: Essential replacement item to prevent costly comebacks or repeat disassembly due to leaking seals.

Technical Specifications

• Manufacturer Part Number / SKU: 46-90075 (aFe BladeRunner / Advanced Flow Engineering)
• Truck Platform: Late 2004–2007 Ford F-250, F-350, F-450, F-550 Super Duty & Ford Excursion
• Engine Platform: 6.0L 32-Valve Powerstroke V8 Turbo Diesel (Square Cooler Configuration)
• Cooler Compatibility: Square-Tube Design (Production Date from September 22, 2003, through 2007)
• Kit Contents: Exhaust Flange Gaskets, Up-Pipe Seals, and Coolant O-Rings
• Core Requirement: None (Brand New Gasket Kit - No Core Return Required)
• Warranty: aFe Power Limited Manufacturer Warranty

Vehicle Fitment & Installation Notes

• Late 2004–2007 Ford F-250 / F-350 / F-450 / F-550 Super Duty – 6.0L Powerstroke Diesel
• Late 2004–2005 Ford Excursion – 6.0L Powerstroke Diesel
• Fits Model Years: Late 2004, 2005, 2006, 2007 (Engine build dates after 09/22/2003)
• Fitment Notice: Engineered strictly for late 2004–2007 models utilizing the square EGR cooler layout. Does not fit early 2003 to mid-2004 trucks equipped with the round cooler design. Always verify your existing hardware configuration before ordering.
• Installation Tip: Completely scrape away all old gasket material from the intake manifold and exhaust up-pipe mounting surfaces. Lightly lubricate coolant O-rings with clean coolant or engine oil during assembly to prevent pinching or binding as hardware is torqued to factory specification.