Sometimes, I come across something that commands I take a second look. Recently, while I was looking for something for Project WorkHorse, I came across something that made me take more than a second look. I Was doing some research about problem areas realized by many truck owners, and that is when I found the H-Core EGR Cooler from Bullet Proof Diesel.

I know many of you think all EGR coolers are created equal, and I used to think that way. So the H-core EGR cooler caused me to do a little more research to see why it’s better than the OE design. H-Core coolers work by using twisted sets of stainless-steel tubing in place of traditional straight or rigid tubes. By twisting the tubing, this allows them to flex and move with temperature change. This greatly reduces stress on the bulkheads and seams. This also allows Bullet Proof Diesel to stack the tubing very close together, allowing for more tubing – and cooler EGR gas — than would be with traditional straight tubes.

The H-Core construction also increases the surface area of the coolant tubes within the cooler making them more effective heat exchangers. Bullet Proof Diesel aims to provide a permanent EGR cooler solution, in contrast to the stock units, which repeatedly need to be replaced in many cases.

The first sign of an EGR cooler failure is steam coming from the exhaust. Although there are several possible sources for this steam, including head gasket failure, a cracked EGR cooler, or condensation inside the exhaust system. When the coolant passages inside your cooler leak, the coolant mixes with the exhaust and enters the intake. This liquid is heated either directly by the exhaust or inside the engine before being pushed out through your truck’s tailpipe.

So you have a choice, you can either wait for a failure and get a new H-Core EGR cooler from Bullet Proof Diesel or be proactive and replace it before it causes a serious issue when it fails.