Engineered specifically for early 2003 and mid-2004 Ford F-250, F-350, F-450, F-550 Super Duty and Excursion trucks equipped with the 6.0L Powerstroke diesel engine utilizing the early round-style EGR cooler configuration (production dates up to September 22, 2003), the Dorman OE Solutions Replacement EGR Cooler (904-260) provides a dependable fix for factory thermal fatigue. Factory original equipment coolers are prone to cracking at internal brazed joints due to extreme exhaust heat cycles and restricted coolant flow, allowing coolant to leak directly into the intake tract and cause white exhaust smoke or engine hydrolock.

Dorman manufactures the 904-260 replacement cooler using high-grade stainless steel materials designed to withstand intense thermal expansion and exhaust pressures. Each unit undergoes strict benchmarking and burst testing to ensure structural integrity. Supplied as a complete kit with all necessary mounting hardware, seals, and gaskets included, this direct-fit replacement restores factory exhaust gas recirculation cooling without requiring core deposits or complicated return shipping.

Key Features & Benefits

• Durable Stainless Steel Build: Constructed from high-quality stainless steel to resist corrosion, high exhaust temperatures, and thermal fatigue.
• Direct OE Fit and Function: Precision-engineered to match original factory mounting dimensions for a seamless drop-in installation on early 6.0L applications.
• Rigorously Tested Quality: Subjected to heat-transfer and burst pressure testing to guarantee reliable performance under demanding driving conditions.
• Complete Hardware Kit Included: Ships with all required gaskets, seals, and O-rings for an immediate, leak-free installation.
• No Core Charge Required: Brand-new aftermarket replacement unit, eliminating the need to return old, contaminated cores.

Technical Specifications

• Manufacturer Part Number / SKU: 904-260 / DOR904-260
• OE / Superseded Interchange Numbers: Ford 3C3Z-9P456-B, 3C3Z9P456B; Cardone 4E-2003; Bostech EGR501; Standard Motor Products ECK12
• Truck Platform: Early 2003–2004 Ford F-250, F-350, F-450, F-550 Super Duty & Ford Excursion
• Engine Platform: 6.0L 32-Valve Powerstroke V8 Turbo Diesel (Round Cooler Configuration)
• Cooler Type: Round-Tube Design (Production Build Date Up to 09/22/2003)
• Material Composition: Heavy-Duty Stainless Steel
• Included Components: EGR Cooler Assembly, Gaskets, O-Rings, and Hardware
• Core Requirement: None (Brand New Unit - No Core Return Required)
• Warranty: Dorman Limited Lifetime Warranty

Vehicle Fitment & Installation Notes

• Early 2003–2004 Ford F-250 / F-350 / F-450 / F-550 Super Duty – 6.0L Powerstroke Diesel (Built up to 09/22/2003)
• Early 2003–2004 Ford Excursion – 6.0L Powerstroke Diesel
• Fits Model Years: Early 2003, 2004 (Engine build dates prior to September 22, 2003)
• Fitment Notice: Designed strictly for early 2003–2004 models equipped with the round EGR cooler. Does not fit late 2004.5–2007 trucks utilizing the square-style cooler (which require part number GA304N or 1090202). Verify your truck's physical cooler shape and engine build date before ordering.
• Installation Tip: Completely drain the engine coolant system, remove the intake manifold and up-pipe carefully, and inspect the engine oil cooler for restrictions. A clogged oil cooler is the primary root cause of repeat EGR cooler failures on the 6.0L platform.