The Alliant Power Square EGR Cooler with Gasket Kit (AP63446) features rigorous OE-standard fit and function testing, complete installation gaskets, and an industry-leading 24-month unlimited-mileage warranty specifically for late 2004–2007 Ford 6.0L Powerstroke trucks.

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 (built after 9/22/2003), the Alliant Power EGR Cooler Kit (AP63446) provides a dependable, direct-replacement solution. Factory OEM coolers frequently rupture under intense exhaust heat and thermal cycling due to restricted coolant flow from clogged engine oil coolers, allowing coolant to leak into the intake system and trigger white smoke or engine hydrolock.

As an authorized Tier-1 OE supplier, Alliant Power manufactures the AP63446 kit to meet or exceed original equipment standards. Each assembly undergoes strict validation for fit, form, and function, and ships complete with the necessary intake and exhaust installation gaskets to ensure a leak-free setup right out of the box.

Key Features & Benefits

• Complete All-in-One Kit: Includes the upgraded replacement square EGR cooler and a matching set of intake and exhaust installation gaskets.
• OE-Standard Validation: Tested rigorously for fit, form, and function to match original equipment performance and emissions compliance.
• Direct Bolt-In Replacement: Precision-machined mounting flanges match factory dimensions exactly for a straightforward under-hood installation.
• Alliant Power 24-Month Warranty: Backed by Alliant's robust 24-month, unlimited-mileage parts warranty for maximum peace of mind.

Technical Specifications

• Manufacturer Part Number / SKU: AP63446 / 012AP63446
• Ford OE Interchange Numbers: Ford 4C3Z-9P456-AC, 4C3Z-9P456-AF, 4C3Z-9P456-AH, 4C3Z-9P456-AJ
• Navistar Interchange Numbers: 1844085, 1844085C7, 1845145C93, 1845145C97, 1845145C99
• 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)
• Included Components: Square EGR Cooler Assembly and Complete Gasket Kit
• Core Requirement: None (Brand New Unit - No Core Return Required)
• Warranty: Alliant Power 24-Month Unlimited Mileage 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 vehicle build date and physical cooler shape before ordering.
• Installation Tip: Completely drain the cooling system, remove the intake manifold and up-pipe carefully, and inspect the engine oil cooler condition. A restricted oil cooler restricts coolant flow to the EGR cooler and will cause repeat thermal failure.