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1. Coolant loss and internal coolant leak One of the most common symptoms of a failing EGR cooler is coolant loss. This can be caused by a leak in the EGR cooler itself or in the hoses that connect it to the engine. In many cases, the coolant loss is internal, which means that you may not see any visible signs of coolant leakage. An internal coolant leak can be caused by a crack in the EGR cooler itself. If there is a crack in the EGR cooler, it can also cause exhaust gases to mix with the coolant, causing the coolant reservoir tank to pressurize. This can lead to the coolant spilling out of the overflow. 2. Overheating If the EGR cooler is not functioning properly, it can cause the engine to run hot. This can lead to overheating and potential engine damage. 3. Decreased fuel economy A faulty EGR cooler can cause the engine to run less efficiently, resulting in decreased fuel economy. 4. Increased exhaust smoke A failing EGR cooler can cause an increase in exhaust smoke, particularly white or blue smoke. Check engine light The engine's computer may detect a problem with the EGR cooler and trigger the check engine light. Diagnostic trouble codes (DTCs) related to the EGR system, such as EGR low flow, EGR efficiency, and EGR differential pressure, may be stored in the engine's computer. 5. Decreased performance If the EGR cooler is not functioning properly, it can lead to decreased engine performance and power. 6. 5mph derate If the EGR cooler becomes plugged with coolant or soot (from age or possibly premature failure), the EGR flow may become so low that the truck cannot complete a regeneration. This can raise the soot level and cause the truck to go into a 5mph derate. It is important to address a failing EGR cooler as soon as possible to avoid this issue

1. Gather the necessary tools and supplies:  To clean the EGR cooler, you'll need a few tools, including a wrench set, a screwdriver set, a coolant draining container (capable of holding up to 14 gallons), and a heavy duty degreaser (1-2 gallons). 2. Disconnect the battery: Before starting any work on the engine, it's important to disconnect the battery to prevent any electrical accidents. 3. Drain the coolant: The first step in cleaning the EGR cooler is to drain the coolant from the engine. Locate the coolant drain valve and use a wrench to open it. Allow the coolant to drain completely into the coolant draining container. 4. Remove the EGR cooler: First, remove the mounting bolts that hold the EGR cooler in place. Next, remove the clamps connecting the EGR cooler to the EGR valve or elbow. Carefully remove the EGR cooler from the engine, and be sure to remove the outlet EGR hose and the inlet and outlet coolant lines. 5. Clean the EGR cooler: Seal the outlet exhaust end of the EGR cooler with a cap, or a DIY plug, or wrap the end with heavy duty plastic wrap and seal it with a clamp. Fill the inlet exhaust end (EGR valve side) of the EGR cooler with the degreaser to the brim. Let it sit for 8-12 hours. Note: This step is a matter of personal preference and depends on the strength of the degreaser. If the degreaser is very strong, it may be safer to simply rinse the EGR cooler instead of letting it soak. Drain the used degreaser into a proper container and dispose of it properly. Rinse the degreaser out of the EGR cooler so there is no residue left. This is important because any residue can cause the soot to build up even more. Make sure the EGR cooler is thoroughly dry before reassembly to prevent water from entering the exhaust system. 6. Test the EGR cooler: Once the EGR cooler is clean, you can test it to make sure it is functioning properly. One way to do this is to perform a backpressure test. This involves using a pressure gauge to measure the amount of pressure exerted on the EGR cooler (if you have access to such tools). 7. Reinstall the EGR cooler: Once the EGR cooler has been cleaned and tested, you can reinstall it on the engine. Be sure to replace any necessary gaskets, seals, hoses, or clamps that are worn or damaged. Tighten the mounting bolts securely and refill the engine with coolant. 8. Test the engine: After the EGR cooler has been reinstalled, start the engine and test it to make sure it is running smoothly. If the engine is running correctly, you can consider the cleaning process a success.