Bullet Proof Diesel 6800100 H-Core EGR Cooler — 2011–2024 Ford 6.7L Power Stroke

Stop replacing cracked OEM EGR coolers. The factory 6.7L Power Stroke cooler is a known weak point — thermal expansion and contraction repeatedly stress the tubes and seams until they fail. Bullet Proof Diesel’s 6800100 is the upgraded, lifetime-warranty solution built to outlast the engine.

Why H-Core lasts

Instead of rigid straight tubes, this cooler uses Bullet Proof’s patented H-Core design: helically wound (twisted) stainless-steel tubes. The tubes flex with heat cycles instead of fighting them, dramatically reducing stress on the bulkheads and welds. The twisted layout also packs more tubing into the same space, improving heat transfer so EGR gases run cooler.

Key features

• Stainless-steel tubes — stronger and more resistant to fatigue and heat-stress failure than OEM
• TIG-welded or vacuum-brazed tube-to-bulkhead joints
• Direct-fit replacement for Ford BC3Z-9V425-A and HC3Z-9V4250-A
• No core charge
• Parts-only lifetime warranty
• CARB EO D-730-5

Gaskets and hardware are not included. Pair it with a dedicated 6.7L EGR cooler gasket/hardware kit for a complete install.

Fitment: 2011–2024 Ford Super Duty trucks with the 6.7L Power Stroke (F-250, F-350, F-450 and similar).

This is the cooler Bullet Proof Diesel designed after years of solving the same problem on the 6.0L. If you want to replace the EGR cooler once and be done, this is it.