Engineered specifically for 2003 through 2007 Ford F-250, F-350, F-450, F-550 Super Duty, Excursion, and 2004–2010 E-Series Van platforms equipped with the 6.0L Powerstroke diesel engine, the Alliant Power EGR Valve O-Ring Kit (AP0005) provides essential high-temperature replacement seals for routine maintenance or EGR valve servicing. When cleaning carbon buildup out of the factory EGR valve or installing a replacement valve, reusing flattened or heat-hardened original O-rings frequently leads to annoying exhaust leaks, soot tracking under the hood, and high-pitched whistling noises under boost.

Alliant Power manufactures these replacement O-rings using specialized high-temperature elastomer compounds designed to withstand continuous exhaust gas heat cycles and oil exposure without shrinking or cracking. Each kit includes all necessary individual seals required to completely reseal the factory EGR valve housing back to original equipment standards.

Key Features & Benefits

• OEM-Matched Quality: Manufactured to strict Ford OE specifications, ensuring correct cross-section dimensions and reliable sealing pressure.
• High-Temperature Elastomer Material: Resists extreme exhaust heat and oil vapors, preventing premature hardening, flattening, and vacuum leaks.
• Prevents Soot Tracking & Whistling: Secures the EGR valve body tightly against the intake manifold, stopping exhaust gas leaks and whistling under acceleration.
• Essential Maintenance Component: Must-replace item whenever removing or cleaning carbon from the factory 6.0L Powerstroke EGR valve.
• Alliant Power 24-Month Warranty: Backed by Alliant's comprehensive unlimited-mileage warranty coverage.

Technical Specifications

• Manufacturer Part Number / SKU: AP0005 / 0005 (Alliant Power)
• Ford OE Interchange Numbers: Ford 3C3Z-9P455-AB, 3C3Z9P455AB; International / Navistar 1840778C91
• Truck & Van Platform: 2003–2007 Ford Super Duty F-250/350/450/550, Excursion & 2004–2010 E-Series Vans
• Engine Platform: 6.0L 32-Valve Powerstroke V8 Diesel / Navistar VT365
• Kit Contents: Complete Set of High-Temperature EGR Valve Body O-Rings
• Core Requirement: None (Brand New Components - No Core Return Required)
• Warranty: Alliant Power 24-Month Unlimited Mileage Warranty

Vehicle Fitment & Installation Notes

• 2003–2007 Ford F-250 / F-350 / F-450 / F-550 Super Duty – 6.0L Powerstroke Diesel
• 2003–2005 Ford Excursion – 6.0L Powerstroke Diesel
• 2004–2010 Ford E-350 / E-450 Super Duty Van – 6.0L Powerstroke Diesel
• Fits Model Years: 2003, 2004, 2005, 2006, 2007 (Plus E-Series vans through 2010)
• Fitment Notice: Compatible with both early round-cooler and late square-cooler 6.0L Powerstroke engine configurations. Always clean the EGR valve bore in the intake manifold of carbon deposits before sliding in the new O-rings.
• Installation Tip: Lightly lubricate the new O-rings with clean engine oil or a thin film of high-temperature grease during installation to prevent pinching or rolling as the EGR valve is pressed into the intake manifold bore.