Engineered specifically for late 2004.5 through 2007 Ford Powerstroke 6.0L diesel engines utilizing the square-style EGR cooler configuration, the Grizzly New Replacement EGR Cooler (GA304N) provides a durable solution to one of the most common failure points on the 6.0L platform. Factory OEM EGR coolers are subjected to severe exhaust thermal cycling and often rupture due to restricted coolant flow caused by clogging in the engine oil cooler. When the stock cooler cracks internally, it leaks engine coolant directly into the intake tract—resulting in white exhaust smoke, unexplained coolant loss, and the risk of catastrophic head gasket failure.

The Grizzly GA304N is manufactured as a brand-new, direct-fit replacement engineered to withstand extreme thermal expansion and exhaust pressures far better than failure-prone factory units. Designed to restore proper exhaust gas cooling before recirculation, each unit is built to strict quality standards and ships complete with the necessary installation gaskets for a leak-free setup. Because it is a brand-new replacement assembly, there are no core charges or complex return paperwork required.

Key Features & Benefits

• Upgraded Internal Construction: Built to withstand severe thermal fatigue and high exhaust gas temperatures, significantly reducing the likelihood of internal cracking.
• Direct Bolt-In OE Replacement: Engineered to match factory mounting points and dimensions precisely for a hassle-free under-hood installation.
• Restores Proper Cooling Function: Lowers exhaust gas temperatures before they re-enter the intake manifold, safeguarding against coolant pressurization and white smoke.
• Brand New with No Core Charge: Eliminates the core return deposit and shipping delays associated with remanufactured units.
• Complete Installation Gaskets Included: Ships with all required gaskets, saving you time and preventing exhaust or coolant leaks at the up-pipe and intake connections.
• CARB Compliant: Retains emissions legal status for street-driven applications.

Technical Specifications

• Manufacturer Part Number / SKU: GA304N (Grizzly Air / GZ-GA304N)
• OEM Cross-Reference Numbers: Ford 4C3Z-9P456-AJ, 4C3Z9P456AJ; International / Navistar 1845145C97
• Truck Platform: 2004.5–2007 Ford Super Duty F-250, F-350, F-450, F-550 & Ford Excursion
• Engine Platform: 6.7-Liter (365 CID) VT365 / 6.0L 32-Valve Powerstroke V8 Turbo Diesel
• Cooler Configuration: Square-Style EGR Cooler Assembly (Mid-2004 to 2007 Late Style)
• Included Components: Replacement EGR Cooler and Intake/Exhaust Gasket Set
• Core Requirement: None (Brand New Unit - No Core Return Required)
• Warranty: Grizzly Limited Manufacturer Warranty

Vehicle Fitment & Installation Notes

• 2004.5–2007 Ford F-250 / F-350 / F-450 / F-550 Super Duty – 6.0L Powerstroke Diesel (Built after 9/29/2003 with Square Cooler)
• 2004.5–2005 Ford Excursion – 6.0L Powerstroke Diesel
• Fits Model Years: Late 2004, 2005, 2006, 2007
• Fitment Notice: Designed strictly for late 2004.5–2007 models utilizing the square EGR cooler. Does not fit early 2003 to mid-2004 trucks equipped with the round-style cooler. Always inspect the engine oil cooler condition prior to installation; a partially clogged oil cooler restricts coolant flow and will cause repeat failure of any replacement EGR cooler.
• Installation Tip: Ensure the cooling system is completely drained and cool before unbolting the intake manifold and up-pipe. Thoroughly clean all mating surfaces, replace the oil cooler if differential temperatures exceed specifications, and torque all hardware to factory sequence and spec.