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Recipe - Cummins 6.7L ISB Diesel (Ram HD)

Specific Fix build

Reliability tier: aggregated - verify before ordering, see /disclosure/

EGR system repair for a 6.7 Cummins with a failed valve and/or cooler (modes EGR valve sooting / failure / EGR cooler failure: soot-clogged valve, coolant-loss cooler). Order era-correct hardware: the early cooler (68003399AA, 2007.5-2009) differs from the 2010+ cooler (68048988AA, year coverage contested - see its part disclosure). Do the valve and cooler together if the cooler has leaked - antifreeze in the intake kills the fresh valve.

Parts

• 6.7 Cummins EGR Valve - the soot-clogged valve is the primary repair; current service PN 68026995AB covers 2007.5-2018 via the supersession chain (qty 1)
• 6.7 Cummins EGR Cooler (2010-2018 design) - 2010+ cooler; if 2007.5-2009 use 6.7 Cummins EGR Cooler (2007.5-2009 design) instead (qty 1)
• 6.7 Cummins EGR Cooler (2007.5-2009 design) - early cooler (2007.5-2009 design); pick by build year, not by truck model (qty 1)
• 6.7 Cummins Spec Coolant + SCA - flush and refill after the cooler swap; keep the era-correct chemistry (HOAT vs OAT) (qty 1)
• egr-gasket (data-gap - no verified part on this platform yet) - new gaskets/hardware at both flanges - re-using soot-set gaskets invites leaks (qty 1)

Install order

1. confirm which EGR failure is present: valve (soot/sticking, codes) vs cooler (external coolant loss / white exhaust / coolant in intake)
2. order era-correct cooler: 2007.5-2009 -> 68003399AA; 2010+ -> 68048988AA and confirm MY2013-2018 applicability by VIN (contested vendor coverage)
3. replace the EGR valve while the intake side is open
4. replace the cooler with new gaskets; clean the intake-side soot sludge
5. flush the cooling system and refill with era-correct coolant; bleed

Expected outcome

EGR flows, no coolant loss, no soot codes; intake free of sludge.

Do not

• do not disable or bypass the EGR system as a 'fix' - this resource covers repair with functional emissions equipment only
• do not re-use coolant spilled during the cooler swap - contamination goes straight back into the fresh cooler
• do not replace the valve only, if the cooler has been leaking antifreeze into the intake - the new valve will coke and stick again

Parts budget

About $650-$2,100 in parts, plus parts we have no price for. It depends on what the diagnosis finds; each option below is what you buy together. Prices marked "at Dave's" are Dave's Auto Center's, the same as in his store; the others are approximate prices from OEM and maker catalogs, rounded (a manufacturer's list price can run higher). Parts only, no labor.

• about $1,600: 6.7 Cummins EGR Valve (about $1,600)
• about $2,100 plus parts we have no price for: 6.7 Cummins EGR Cooler (2010-2018 design) (about $2,100) + 6.7 Cummins Spec Coolant + SCA (no price yet) + egr gasket (no price yet)
• about $650 plus parts we have no price for: 6.7 Cummins EGR Cooler (2007.5-2009 design) (about $650) + 6.7 Cummins Spec Coolant + SCA (no price yet) + egr gasket (no price yet)

DIY or shop: Either: a confident DIY can do it in a long weekend; intake removal, coolant handling and bleeding make it a shop job for most owners.