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Power Junky
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1,054 Posts
Discussion Starter #1
Which egr cooler is better in design and least likely to fail. Round or square? My vote goes to the round cooler. What do yall think?
 

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The Unseen Mod
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4,126 Posts
The different in round and square was also the year difference as well.
 

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Power Junky
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1,054 Posts
Discussion Starter #3
Yup, which egr cooler is better though? Less likely to fail in stock form?
 

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PSN Veteran
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2,983 Posts
IIRC the early years are round are seemed to be better with less failures. :shrug:
 

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Word
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608 Posts
Round is the best of the two...I believe they only came on the 03 and early 04 models...
 

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Wondering what if
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828 Posts
In Diesel Power mag some time ago, there was an article about a shop in So Cal that believed the round was better. They some how changed out the failing squares to the rounds. Showed pics of alot of coolers they had changed over the years.
 

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It wasn't me
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1,232 Posts
In Diesel Power mag some time ago, there was an article about a shop in So Cal that believed the round was better. They some how changed out the failing squares to the rounds. Showed pics of alot of coolers they had changed over the years.
Remember the round coolers were in 03 and early 04 trucks... the square coolers were in 04.5, 05, 06, 07 so there are a lot more square coolers on the road.
 

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Power Junky
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1,054 Posts
Discussion Starter #9
More dosent make them better. The difference is because honeywell or garret made the early egr coolers. I would guess they lost the contract and another company came in cheaper. That is why they changed. Ih engines saw lower temps I would bet due to lower hp tuning and less rpms.
 

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it's an 02 05 08
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930 Posts
:whs: i have been replacing more of the round style coolers lately,dont think there is a difference in the round or the square besides year model
 

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Word
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608 Posts
More dosent make them better. The difference is because honeywell or garret made the early egr coolers. I would guess they lost the contract and another company came in cheaper. That is why they changed. Ih engines saw lower temps I would bet due to lower hp tuning and less rpms.
You're exactly right, the round coolers were manufactured by a different company....the inside tubes of the square coolers were junk, the welds were junk as well....the only reason Ford went to square coolers was because of a cheaper manufacturing price....Here's another Ford cheapo secret, all those wiring harness chaffing issues was due to the fact the Ford did not use the wiring harness that International had provided them, instead some engineer figured out a way to route the harness so that it used less wire, by cutting 1 foot of copper out of every wiring harness they could save millions on manufacturing in the long run...we see how that worked out !!!!! Just remember that everything you drive or fly in was built by the lowest bidder...
 

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It wasn't me
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1,232 Posts
More dosent make them better. The difference is because honeywell or garret made the early egr coolers. I would guess they lost the contract and another company came in cheaper. That is why they changed. Ih engines saw lower temps I would bet due to lower hp tuning and less rpms.
I wasn't meaning more makes them better. I was meaning you will see more failed square coolers because there are so many more on the road.
 
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