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Recipe - Ford 6.7L Power Stroke Diesel (Scorpion)

Specific Fix build

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

EGR repair by generation (modes EGR valve soot clogging / sticking / EGR cooler thermal-fatigue coolant leak): the 6.7's EGR hardware is generation- AND frame-split. Gen1/Gen2 valves differ Pickup (Wide Frame) vs Chassis Cab (Narrow Frame) until 2017 unified them (HC3Z-9D475-D, 2017-2019); Gen3 got its own valve (HC3Z-9D475-C). Coolers: gen1/gen2 (BC3Z-9V425-A) vs gen3 (HC3Z-9V425-B) are different assemblies. Order by build date and frame, not by model year alone.

Parts

• 6.7L Power Stroke EGR Valve, Pickup (Wide Frame), 2015 to mid-2016 production - gen1/gen2 Pickup (Wide Frame) valve, to mid-2016 production (qty 1)
• 6.7L Power Stroke EGR Valve, Chassis Cab (Narrow Frame), 2015 to mid-2016 production - Service Kit - gen1/gen2 Chassis Cab (Narrow Frame) valve, service kit form (qty 1)
• 6.7L Power Stroke EGR Valve, Pickup + Chassis Cab (unified), 2017-2019 - the 2017-2019 unified valve (HC3Z-9D475-D) - both frames (qty 1)
• 6.7L Power Stroke EGR Valve, Pickup (Wide Frame), gen3 - gen3 valve (2020+) (qty 1)
• 6.7L Power Stroke EGR Cooler (Heat Exchanger), gen1/gen2 - gen1/gen2 cooler (2011-2019 era design) (qty 1)
• 6.7L Power Stroke EGR Cooler (Heat Exchanger), gen3 - gen3 cooler (2020+) (qty 1)
• EGR Cooler Seal Kit (current service PN BC3Z-9P455-B) - fresh seal kit (BC3Z-9P455-B) at every cooler opening (qty 1)

Install order

1. place the truck: generation (2011-14/15-19/2020+) x frame (Pickup vs Chassis Cab to 2016)
2. order the era-and-frame-correct valve
3. cooler where coolant symptoms exist - generation-correct assembly
4. new seal kit, clean intake soot, coolant flush and bleed if the cooler leaked

Expected outcome

EGR flows clean, no coolant loss, codes clear.

Do not

• do not order a valve by model year alone - the Wide/Narrow Frame split to 2016 and the 2017 unification are real hardware differences

Parts budget

About $270-$910 in parts. 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 $440: 6.7L Power Stroke EGR Valve, Pickup (Wide Frame), 2015 to mid-2016 production (about $440)
• about $440: 6.7L Power Stroke EGR Valve, Chassis Cab (Narrow Frame), 2015 to mid-2016 production - Service Kit (about $440)
• about $460: 6.7L Power Stroke EGR Valve, Pickup + Chassis Cab (unified), 2017-2019 (about $460)
• about $270: 6.7L Power Stroke EGR Valve, Pickup (Wide Frame), gen3 (about $270)
• about $910: 6.7L Power Stroke EGR Cooler (Heat Exchanger), gen1/gen2 (about $800) + EGR Cooler Seal Kit (current service PN BC3Z-9P455-B) (about $110)
• about $450: 6.7L Power Stroke EGR Cooler (Heat Exchanger), gen3 (about $340) + EGR Cooler Seal Kit (current service PN BC3Z-9P455-B) (about $110)

DIY or shop: Shop: intake-side work with coolant handling.