This procedure covers the removal and replacement of the EGR cooler on the 2021-2024 Ford F-150 with the 3.5L V6 EcoBoost engine, including exhaust component removal and coolant system drainage.

Warnings

Tools required

Parts

• EGR cooler assembly × 1 — Use OEM Ford specification
• EGR cooler gasket kit × 1 — Use OEM Ford specification
• Exhaust flange gaskets × 2 — Use OEM Ford specification
• EGR cooler coolant hose clamps × 4 — Replace if damaged

Fluids

• Motorcraft Orange Coolant — 2 qt

Preparation

1. Ensure engine is completely cold (minimum 2 hours after last operation)
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery cable and wait 5 minutes for airbag system to discharge
4. Remove engine cover by pulling upward on front clips and releasing rear retaining tabs
5. Place coolant drain pan under radiator drain petcock on driver side of radiator
6. Open radiator drain petcock and remove radiator cap to drain coolant (approximately 3 gallons will drain)
7. Apply penetrating oil to exhaust flange bolts and oxygen sensor threads, allow 15 minutes to penetrate

Procedure

1. 1

   Remove right-side oxygen sensor
   Disconnect the oxygen sensor electrical connector located near the right exhaust manifold. Using an oxygen sensor socket, turn counterclockwise to remove the oxygen sensor from the exhaust pipe. Set aside for reinstallation.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
2. 2

   Disconnect EGR valve electrical connector
   Locate the EGR valve on top of the EGR cooler assembly. Press the locking tab and disconnect the electrical connector from the EGR valve. Move wiring harness aside to prevent damage.
3. 3

   Remove EGR valve mounting bolts
   Remove the two mounting bolts securing the EGR valve to the EGR cooler using a 10mm socket. Carefully lift the EGR valve away from the cooler. Note the gasket orientation and discard the old gasket.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
4. 4

   Remove exhaust heat shields
   Remove the heat shield bolts securing the right-side exhaust heat shields using an 8mm socket. Remove heat shields to access the EGR cooler exhaust connections. There are typically 4-6 bolts depending on configuration.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
5. 5

   Disconnect EGR cooler inlet exhaust flange
   Locate the exhaust flange connecting the right exhaust manifold to the EGR cooler inlet. Remove the two exhaust flange bolts using a 13mm socket. Support the EGR cooler to prevent it from dropping. Discard the old gasket.
   ⚠Exhaust flange may be seized due to heat cycling. Do not force. Apply additional penetrating oil if needed.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
6. 6

   Disconnect EGR cooler outlet exhaust flange
   Locate the exhaust flange connecting the EGR cooler outlet to the downstream exhaust pipe. Remove the two flange bolts using a 13mm socket. Separate the connection and discard the old gasket.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
7. 7

   Release coolant hose clamps
   Using a flathead screwdriver or hose clamp pliers, release the spring clamps or worm-gear clamps on both the inlet and outlet coolant hoses connected to the EGR cooler. Slide clamps away from the cooler connections. Have a drain pan ready as residual coolant will drain.
   ⚠Residual coolant will drain from hoses (approximately 1 quart). Position drain pan to catch coolant.
8. 8

   Disconnect coolant hoses from EGR cooler
   Twist the coolant hoses to break the seal, then pull firmly to disconnect from the EGR cooler inlet and outlet ports. Allow residual coolant to drain completely into the drain pan. Inspect hoses for damage or cracking.
9. 9

   Remove EGR cooler hanger bolts
   Remove the hanger bolts securing the EGR cooler to the mounting bracket on the engine block. There are typically two hanger bolts accessed from above. Use a 13mm socket.
   Torque spec

   Hanger Bolts23 Nm (17 lb-ft)
10. 10

    Remove EGR cooler assembly
    Carefully maneuver the EGR cooler assembly out of the engine bay. Route it past wiring harnesses and coolant hoses. The cooler must be tilted and rotated to clear surrounding components. Inspect all mounting points and gasket surfaces on the engine for damage or excessive carbon buildup.
11. 11

    Clean mounting surfaces
    Using a plastic scraper or brass brush, clean all gasket surfaces on the exhaust flanges and EGR valve mounting surface. Remove all carbon deposits and old gasket material. Use shop vacuum or compressed air to remove debris. Do not allow debris to enter exhaust or coolant passages.
    ℹ️Do not use steel scrapers on aluminum surfaces as this will cause damage. Use plastic scrapers only.
12. 12

    Prepare new EGR cooler
    Inspect the new EGR cooler for shipping damage. Install new gaskets onto the exhaust inlet and outlet flanges. Ensure gaskets are properly seated. Apply a thin coat of anti-seize compound to all exhaust flange bolt threads.
13. 13

    Install new EGR cooler assembly
    Carefully maneuver the new EGR cooler into position, reversing the removal path. Align the coolant port connections and exhaust flange bolt holes. Start the hanger bolts finger-tight to support the assembly. Align both exhaust flanges before tightening any fasteners.
14. 14

    Install and torque hanger bolts
    Torque the EGR cooler hanger bolts to specification using a torque wrench. Tighten in an alternating pattern if multiple bolts are present.
    Torque spec

    Hanger Bolts23 Nm (17 lb-ft)
15. 15

    Install and torque exhaust flange connections
    Install new exhaust flange gaskets at both the inlet and outlet connections. Install flange bolts with anti-seize compound on threads. Torque the inlet flange bolts (to exhaust manifold) to 45 Nm and outlet flange bolts to 55 Nm. Ensure flanges are fully seated before torquing.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
16. 16

    Connect coolant hoses
    Reconnect the coolant inlet and outlet hoses to the EGR cooler ports. Push hoses fully onto the ports until they seat completely. Reposition the hose clamps over the connection points and tighten securely. Verify hoses are fully seated and clamps are positioned correctly.
17. 17

    Install EGR valve
    Position a new gasket on the EGR cooler mounting surface. Install the EGR valve and start both mounting bolts finger-tight. Torque mounting bolts to specification in an alternating pattern. Reconnect the EGR valve electrical connector and verify it clicks into place.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
18. 18

    Reinstall oxygen sensor
    Apply a thin coat of anti-seize compound to the oxygen sensor threads (threads only, keep sensor tip clean). Install the oxygen sensor and torque to specification. Reconnect the electrical connector.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
19. 19

    Reinstall heat shields
    Reinstall the exhaust heat shields in reverse order of removal. Install and torque heat shield bolts to specification.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
20. 20

    Refill cooling system
    Close the radiator drain petcock. Using a coolant refill funnel, slowly add Motorcraft Orange coolant to the radiator and coolant reservoir. Fill the radiator to the top and the reservoir to the COLD FILL line. Allow coolant to settle for 5 minutes and top off as needed.
    ⚠Use only Motorcraft Orange coolant. Do not mix with other coolant types.
21. 21

    Bleed cooling system
    With the radiator cap off and funnel installed, start the engine and allow it to warm up to operating temperature while monitoring coolant level. Add coolant as air purges from the system. Run engine until the thermostat opens and coolant circulates through the system (approximately 10-15 minutes). Maintain coolant level in the funnel throughout this process.
22. 22

    Final system check
    Turn off engine and allow to cool for 10 minutes. Remove funnel and install radiator cap. Fill coolant reservoir to HOT FILL line. Inspect all connections for coolant or exhaust leaks. Wipe all surfaces dry for easier leak detection during verification.

Reassembly

1. Reinstall engine cover by aligning rear tabs first, then pressing down on front clips until they click into place
2. Reconnect negative battery cable
3. Verify all tools and parts have been removed from engine bay
4. Check coolant level in reservoir and verify it is at the appropriate level for engine temperature

Verification

• Start engine and verify no Check Engine Light or EGR-related fault codes using an OBD-II scanner
• Allow engine to reach operating temperature and verify cooling fans cycle normally
• Inspect all exhaust flange connections for exhaust leaks (listen for hissing and look for soot traces)
• Inspect all coolant connections on EGR cooler for coolant leaks while engine is at operating temperature
• Rev engine to 2000 RPM briefly and verify no exhaust leaks develop under increased pressure
• After test drive, recheck coolant level when engine is cold and top off to COLD FILL line if needed
• Verify no coolant spots or drips under vehicle after overnight parking

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