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What the EGR System Does and Where It Sits

The EGR (exhaust gas recirculation) system sends a portion of exhaust back into the intake to lower combustion temperature and reduce NOx. An EGR cooler uses engine coolant to cool that exhaust before it reaches the intake.

On the 6.7L, Ford's workshop description places the EGR cooler on the right (passenger) side of the engine, with the EGR valve and its motor at the right front. Ford also describes two separate cooling systems on this engine: a primary high-temperature system, and a secondary low-temperature system that cools the charge air cooler, fuel cooler, EGR cooler, and transmission oil cooler. Each system has its own radiator, coolant pump, thermostats, and degas bottle.

That matters for diagnosis. If you are losing coolant, you need to know which degas bottle is dropping.

What Ford Has Documented

Two Ford documents are worth knowing about:

  • Technical Service Bulletin 13-6-5 covers 2011 to 2012 Super Duty trucks with the 6.7L diesel that show a check engine light with P0401. Ford states the concern may be caused by a restricted EGR cooler core.
  • Customer Satisfaction Program 21M04 covers certain 2011 to 2014 Super Duty trucks with the 6.7L diesel, built from November 3, 2009 through March 14, 2014. Ford's stated reason is that the EGR cooler can become plugged with hydrocarbon or soot at high mileage. The program provided a no-cost cooler repair when P0401 and/or P2457 were stored, for 11 years or 120,000 miles from the vehicle's warranty start date, whichever came first.

The program has time and mileage limits, so ask a Ford dealer to check your VIN for any remaining coverage before you pay for a cooler yourself.

Symptoms and Codes

The symptom Ford documents is an illuminated malfunction indicator light with these codes stored:

Code What it points to
P0401 The code Ford ties to a restricted EGR cooler core in TSB 13-6-5
P2457 The code Ford checks during the key on, engine running (KOER) self test to confirm the cooler

Two other signs call for a shop visit right away:

  • Coolant level that keeps dropping with no visible leak. Several components can cause this, and the EGR cooler is one of them.
  • White smoke from the exhaust.

Do not clear the codes and keep driving. Get the cause identified first.

Diagnose Before You Buy Parts

P0401 alone does not prove the cooler is bad. Ford's own procedure in TSB 13-6-5 has two checks:

  1. Read all stored codes with a scan tool. If P0401 is present with no other EGR-related codes, continue.
  2. Run the KOER self test. If P2457 shows up, Ford's step is to replace the EGR cooler core. If it does not, the bulletin does not apply and the concern goes through Ford's powertrain diagnosis manual instead.

If your concern is coolant loss, have a shop pressure test the cooling system, and make sure they check the right system. The primary and secondary systems have separate degas bottles.

This is work for a shop with the right scan tool and Ford's service information.

Your Options

Repair or replace the cooler

If the diagnosis points to the cooler, a Ford dealer or qualified diesel shop can replace it. Ask for the cooling system to be inspected at the same time. Ask about CSP 21M04 first if your truck is a 2011 to 2014 build.

EGR delete kit, for off-road use only

Important: EGR delete kits and delete tuners are intended only for off-road, race, or non-public-road use where permitted. Removing or disabling emissions equipment on a vehicle used on public roads violates the federal Clean Air Act and many state laws, and an off-road label does not change how an EPA-certified vehicle is treated under federal law. Customers are responsible for confirming compliance with federal, state, and local laws before purchase and installation.

If you have a dedicated off-road or competition truck, an EGR delete kit replaces the EGR valve and cooler plumbing with block-off hardware. Because the EGR cooler is part of the engine's coolant circuit, a proper kit has to keep coolant flowing. EngineGo's 2015 to 2016 listings include a coolant bypass, and the 2011 to 2014 listings use a flow-through plate.

EngineGo lists 6.7L Power Stroke EGR kits by build range:

  • 2011 to 2014
  • 2015 to 2016
  • 2017 to 2023

Pick the range that matches your build date. The hardware differs between ranges, so a kit for one range will not fit another. See the full 6.7 Powerstroke EGR delete kit lineup.

The truck also needs a matching tune. The PCM has to be recalibrated so it does not command EGR for hardware that is no longer there. Hardware without a matching tune will set codes.

Installation involves the cooling system, so it is not a beginner job. If you are not comfortable working on coolant lines and refilling and bleeding a cooling system, have a shop do it.

FAQs

Does P0401 always mean the EGR cooler is bad?

No. Ford's bulletin has a technician confirm the cooler with a KOER self test before replacing it. If P2457 does not appear, the bulletin does not apply and other causes get checked. For more on the code itself, see our P0401 guide.

Is the EGR cooler repair still covered by Ford?

It depends on your VIN, build date, and how much time and mileage the vehicle has. CSP 21M04 covered certain 2011 to 2014 builds for 11 years or 120,000 miles from warranty start. A Ford dealer can look up your VIN in Ford's system and tell you what applies.

Where is the EGR valve on a 6.7 Powerstroke?

Ford's workshop description lists the EGR cooler on the right side of the engine and the EGR valve at the right front. That is the passenger side on these trucks.

Do I need a tune with an EGR delete?

Yes. The PCM has to be recalibrated so it does not command EGR or flag hardware that is no longer installed. Running a kit without a matching tune sets codes.

Is an EGR delete legal?

Not for on-road use. Removing or disabling emissions equipment on a vehicle used on public roads violates the federal Clean Air Act and many state laws. An off-road use disclaimer does not change how an EPA-certified vehicle is treated under federal law. Check federal, state, and local rules for your situation before buying or installing anything.

Which kit do I need if I want a complete setup?

That depends on whether you want EGR only or EGR, DPF, and DEF together with a tuner. Our 6.7 Powerstroke delete kit buying guide walks through the options, and the 2011 to 2019 buyer's guide covers year-specific fitment.

Shipping and Returns

Most orders are processed the same or next business day, excluding Sundays, unless otherwise stated. Most packages are delivered within 3 to 5 business days after leaving the warehouse, depending on package size, location, and carrier conditions.

Returns are accepted within 45 calendar days of delivery on unused, uninstalled parts in original condition with all included hardware. Installed, modified, or damaged parts may not be returnable. Electronic parts and tuners may have stricter return limits, and kits that include a tuner may differ. Return shipping may be the customer's responsibility on returns for buyer's reasons. Contact us for an RMA before shipping anything back.

Next Step

Send us your VIN and build date, and tell us whether the truck is a dedicated off-road build. We will confirm which 6.7L Power Stroke kit range fits your truck before you order.