Product Description
The BD DIESEL 1090202 6.0L Power Stroke EGR Cooler Replacement is a heavy-duty exchange cooler engineered for Ford 6.0L Power Stroke diesel trucks and vans built from late 2003 through 2007 with the square tube EGR cooler configuration. This cooler uses TIG-welded 304L stainless tubes to replace the weak OEM brazed cooler cores that are prone to failure and can lead to coolant leaking into the engine and hydrolock damage.
The BD Diesel EGR cooler includes water deflectors to increase coolant flow turbulence and heat dissipation, helping reduce exhaust gas temperatures and prolonging engine life. Each unit is pressure tested and includes the proper O-ring and threaded insert for reliable sealing and performance without triggering engine fault codes.
Fitment
- 2004–2007 Ford F-250 Super Duty – 6.0L Power Stroke
- 2004–2007 Ford F-350 Super Duty – 6.0L Power Stroke
- 2004–2007 Ford E-Series Vans – 6.0L Power Stroke
Note: Designed for vehicles produced after 09/22/2003 with the EGR cooler square tube configuration.
Cross-Reference / Compatible BD DIESEL Products
- BD DIESEL 1090201 EGR COOLER REPLACEMENT – FORD 2003–2004 (ROUND TUBE)
- BD DIESEL 1900204 EGR COOLER GASKET KIT – FORD 2004–2007
FAQ
Why replace the OEM EGR cooler on 6.0L Power Stroke?
The OEM cooler cores are brazed and prone to failure. When they break down, coolant can enter the cylinders and cause hydrolock or head gasket failure. The BD Diesel cooler replaces the weak core with TIG-welded stainless tubes to improve durability and prevent failure.
Will this cooler trigger check engine lights?
No. The BD Diesel cooler is designed as a direct replacement with correct fittings and does not require a performance tuner or cause engine fault codes.
Does the kit include installation hardware?
Yes — the cooler includes the proper O-ring and threaded insert for sealing. Additional gasket kits are available as a complementary BD Diesel product.
Specifications for BD DIESEL PRODUCTS 1090202
| Specification | Details |
|---|---|
| Brand | BD Diesel Performance |
| Part Number | 1090202 |
| UPC | 990011403535 |
| GTIN | 990011403535 |
| Shipping Info | Ships as a single heavy duty EGR cooler unit |
| Prop 65 | This product may be subject to Prop 65. See www.P65Warnings.ca.gov |
