EGR, engine by engine
Exhaust gas recirculation routes a measured share of exhaust back into the intake to cut NOx - and it is the one system that most diesels on this site share, and two of the gas engines as well. It is also a system that punishes neglect: coolers leak coolant into places coolant should not be, valves stick with soot, intakes coke up. The 6.0 Power Stroke made the failure famous; most makers since have their own version of it.
This page groups what our records document, engine by engine: the documented EGR failure modes with their provenance tiers, the components on record with Dave's prices where Dave's lists them, and the recalls whose own text names the EGR system. An engine not named on this page has no EGR failure on record; the one engine our records show without EGR is listed at the bottom.
Every row is a published record - see /disclosure/
6.0 Power Stroke
- EGR cooler failure verified - near-universal; white, sweet-smelling smoke from the exhaust on acceleration or at idle
Components on record: 4C3Z-9P456-AJ, 6.0L Power Stroke Square EGR Cooler Upgrade (Bullet Proof Diesel, 2004.25-2007) - from $365.00. Priced failures: /repair-costs/.
6.4 Power Stroke
- EGR cooler failure -> #8 hydrolock verified - common; white smoke, coolant loss, then the classic: no-crank hydrolock after shutdown (cooler drips into #8 overnight)
Components on record: 8C3Z-9P456-C. Priced failures: /repair-costs/.
6.7 Power Stroke
- EGR cooler thermal-fatigue coolant leak verified - common; white, sweet-smelling exhaust smoke, especially at idle after warm-up
- EGR valve soot clogging / sticking verified - common; rough idle, hesitation, or surging as a sticking valve mismeters exhaust gas
Components on record: BC3Z-9V425-A, HC3Z-9V425-B, BC3Z-9D475-J, 6.7L Power Stroke EGR Cooler Upgrade with H-Core Technology, 2011-2024 (Bullet Proof Diesel) - $1050.00. Priced failures: /repair-costs/.
6.7 Cummins 2007.5-2018
- EGR cooler failure verified - common; white sweet-smelling smoke, coolant loss with no external leak
- EGR valve sooting / failure verified - common; EGR flow DTCs (P0401/P0402/P0404-family), check-engine light
Components on record: 68003399AA, 68048988AA, 68026995AB - recalls naming the EGR system: 08V-641 (December 5, 2008). Priced failures: /repair-costs/.
6.7 Cummins 2019+
- EGR cooler failure (2019+ 6.7) verified - common; coolant drop with no external leak; white smoke on cold start
Components on record: 4627647AG. Priced failures: /repair-costs/.
Duramax L5P
- EGR carbon buildup (valve and intake deposits) aggregated - common; gradual rough idle / drivability degradation over high mileage rather than sudden failure
Components on record: 12720269. Priced failures: /repair-costs/.
Duramax LML
- EGR valve / cooler carbon and coolant service (LML) aggregated - occasional; EGR flow codes, hesitation under load
Components on record: 12635707. Priced failures: /repair-costs/.
Duramax LB7-LMM
- EGR cooler clogging / failure (LB7-LMM) aggregated - common; overheating under load - the LLY-era heat reputation in the owner record
Components on record: 98034351. Priced failures: /repair-costs/.
Duramax 3.0 (LM2/LZ0)
- EGR system failures: valve, cooler, wiring (derate-prone) verified - occasional; check engine / 'Service Emission System' message, often with a speed limitation (65 mph) derate
Components on record: 55513487. Priced failures: /repair-costs/.
3.0 EcoDiesel A630 (Ram 1500 / Grand Cherokee)
- EGR cooler cracking and coolant loss (recalls 19V-757 Ram / 20V-699 Grand Cherokee) verified - common; coolant loss with no visible external leak (microscopic cooler cracks consume coolant through the EGR diffuser path)
Components on record: 68445601AA - recalls naming the EGR system: 20V-699 (November 12, 2020), 19V-757 (October 24, 2019). Priced failures: /repair-costs/.
3.0 EcoDiesel gen3 (Ram 1500 / Wrangler / Gladiator)
- EGR carbon and DPF regeneration faults (dual-loop EGR maintenance burden) aggregated - occasional; EGR performance codes (P2457 family) and carbon-restricted EGR valves/cooler from the dual-loop (high + low pressure) circuit
Components on record: .
3.0 Power Stroke (F-150)
- EGR bypass valve / EGR cooler faults (recall 20E04) verified - common; check engine with EGR codes - P2457 (cooler performance) points at a clogged cooler, bypass-valve codes at the valve
Components on record: JL3Z-9U438-A. Priced failures: /repair-costs/.
3.2 Power Stroke (Transit)
- EGR cooler failure: overheating and coolant loss (three Ford field actions) aggregated - very-common; engine overheating with no obvious cause
Components on record: CK4Z-9U433-D.
ProMaster EcoDiesel
- EGR system: coking and the cooler-with-valve assembly aggregated - occasional; EGR flow DTCs, rough idle, haze on cold start
Components on record: 68771430AA. Priced failures: /repair-costs/.
Sprinter 3.0 V6 (OM642)
- EGR valve and intake coking aggregated - common; EGR flow DTCs, rough idle and haze on cold start
Components on record: 642-140-21-75, 642-140-14-60-64.
Sprinter 2.1 (OM651)
- EGR system: coking and cooler coolant leak aggregated - common; white smoke on cold start, unexplained coolant loss
Components on record: 651-140-07-00.
Triton gas V8 (F-250/F-350)
- EGR system faults / DPFE sensor failure (gas) verified - very-common; P0401 (insufficient EGR flow) / P0402 (excessive) with rough idle
Components on record: EGR Valve, gas engines.
6.4 HEMI (gas)
- EGR valve carbon (gas EGR service surface) aggregated - occasional; EGR flow / position codes, rough idle or hesitation at light load
Components on record: ram-hemi-6_4: emissions (service item). Priced failures: /repair-costs/.
Engines without EGR (1)
- 7.3 Power Stroke - 1994.5-2003 - no EGR on record; exhaust-gas recirculation arrived on this line with the 6.0 in 2003
Prices are Dave's Auto Center retail, the same as in his store (the only seller this site links); a component without a price is a record with no live listing - the part page says what is known. Open the failure page before buying anything, and mind the tier on every fact. Whether a recall is still open on a specific VIN is not known here - nhtsa.gov/recalls.