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 build dates up to September 22, 2003), the Pacific Performance Engineering (PPE) Heavy-Duty Round Replacement EGR Cooler (316129503) provides a permanent upgrade against factory thermal failure. Stock round coolers feature a weak internal honeycomb design that is prone to collecting carbon soot, restricting coolant flow, and cracking under intense exhaust expansion—allowing coolant to leak into the intake and cause white smoke or engine hydrolock.

PPE replaces the failure-prone factory matrix with a robust multi-tube internal design featuring seamless 316 stainless steel tubes enclosed in a heavy-duty 304 stainless housing. This upgraded architecture dramatically improves coolant circulation and exhaust heat dissipation, virtually eliminating thermal cracking and clogging. Fully CARB-compliant across all 50 states, this direct-replacement cooler installs easily with the included gaskets and hardware.

Key Features & Benefits

• Robust Multi-Tube Core: Replaces fragile factory honeycomb interiors with high-flow internal stainless steel tubes to maximize thermal transfer and flow capacity.
• Heavy-Duty 304/316 Construction: Premium seamless stainless steel housing resists high exhaust temperatures, thermal shock, and internal corrosion.
• 50-State CARB Emissions Legal: Features Executive Order (E.O. D-701-7) compliance for street-legal operation nationwide.
• Eliminates Thermal Cracking & Clogging: Enhanced internal passageways prevent soot buildup and withstand aggressive engine duty cycles.
• Complete Gasket Kit Included: Supplied with all necessary mounting gaskets and seals for a straightforward, leak-free installation.

Technical Specifications

• Manufacturer Part Number / SKU: 316129503 / PPE-316129503
• CARB Executive Order Number: E.O. D-701-7 (50-State Legal)
• Truck Platform: Early 2003–2004 Ford Super Duty F-250, F-350, F-450, F-550 & Ford Excursion
• Engine Platform: 6.0L 32-Valve Powerstroke V8 Diesel / Navistar VT365 (Round Cooler Layout)
• Core Design: Multi-Tube Internal Passage Configuration (316 Stainless Steel Tubes with 304 Housing)
• Included Components: Replacement EGR Cooler and Installation Gasket Set
• Core Requirement: None (Brand New Unit - No Core Return Required)
• Warranty: PPE Limited Manufacturer 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 layout (which require part number 316129504). Always 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.