Engineered specifically for 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 utilizing the square-style EGR cooler configuration, the BD Diesel EGR Cooler Gasket Kit (1900204) supplies all necessary interface seals for a complete and reliable installation. Reusing compressed or heat-degraded factory gaskets during an EGR cooler swap is a primary cause of exhaust leaks, under-hood soot blow-by, and coolant loss.

BD Diesel packages this kit with precision-molded components designed to match factory thermal expansion rates and high clamping loads. By including all required up-pipe seals, intake manifold gaskets, and coolant passage O-rings, this kit ensures complete sealing integrity across all fluid and gas boundaries during major emissions service.

Key Features & Benefits

• Complete Seal Assortment: Includes all necessary exhaust gaskets, intake manifold seals, and coolant O-rings required for a full EGR cooler overhaul.
• High-Temperature Materials: Formulated to withstand intense exhaust temperatures and chemical degradation from engine coolants.
• Prevents Exhaust Leaks & Soot Blow-By: Secures up-pipe and manifold interfaces tightly to eliminate whistling noises and exhaust odors.
• Precision Fit for Square Coolers: Tailored specifically for late 2004–2007 square-style EGR cooler assemblies and related tube interfaces.
• Reliable Maintenance Insurance: Essential kit to install alongside any new or upgraded aftermarket EGR cooler to prevent rework.

Technical Specifications

• Manufacturer Part Number / SKU: 1900204 / BDD-1900204
• 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, Coolant O-Rings, and Mounting Hardware
• Core Requirement: None (Brand New Gasket Kit - No Core Return Required)
• Warranty: BD Diesel Limited Parts 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. Does not fit early 2003 to mid-2004 trucks equipped with the round cooler design. Always clean old gasket material completely off all mating surfaces before reassembly.
• Installation Tip: Ensure all mounting flanges on the intake manifold and exhaust up-pipe are free of carbon buildup. Lightly coat coolant O-rings with clean coolant or engine oil to prevent pinching during final torque procedures.