2003-2007 Ford 6.0 liter Diesel Oil Cooler replacement procedure and EGR Cooler partial delete

I've done these.  Its not that hard a job.  But it is a very TIME consuming job and you have to be organized and have patience, else you could damage your truck and expose yourself to it not working.

This link has these videos summarized into a step by step that is helpful.

https://www.docdroid.net/nRu93NO/ford-60-oilcooler-replacment.pdf.html

The steps come from the videos below, which both detail the process of the oil cooler replacement.  A wealth of information in both videos.  If you are tackling this process yourself, they are a must watch and study!

YOUTUBE

srmastertech.  https://www.youtube.com/watch?v=fHyEo3wZ9uA

Diesel Tech Ron.  https://www.youtube.com/watch?v=y8Ba7A08VNo

The recommendation I can make is to always use OEM Ford Parts whenever possible.

Especially the oil cooler and the important gasket kits that come with this part.

DO NOT CHEAP ON NON MOTORCRAFT PARTS.

You don't need specialized tools to do this.  Metric sockets and hand tools will work just fine.

This wouldn't be a job I would tackle if you are not mechanically inclined or have never done mechanical work before.  At very least you'll want to have a good close friend who is to give help.

A recommendation by many who do this job is to also perform whats known as a "partial delete" of your EGR system in these trucks (you should investigate emission regulations in your area).  The 6.0 EGR is notoriously prone to failures and doing this while you have this large component removed from the engine can save a lot of headaches down the road.  The only thing that is special about this is you will need to have some ports of it blocked off using a TIG welder.

The partial keeps everything looking factory, and keeps expensive exhaust components properly mounted.