Author: Lawrence Z, Diesel Performance Specialist at DPFexhaust
⚠️ LEGAL DISCLAIMER: OFF-ROAD USE ONLY
The following content discusses the removal of emissions equipment, which is intended solely for off-road competition use. Modifying emission systems is illegal for street use in the United States and may result in penalties, voided warranties, and failure of state inspections. Consult your local laws before proceeding.
If you own a 2015 Ford F-350 with the 6.7L Powerstroke, you’re already familiar with the emissions headache. When transitioning to a competition-only setup, the question isn't if you should remove the EGR system, but how.
You’ve narrowed your choices to two common kit types:
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Pass-Through Kits: Block off the EGR flow but leave the bulky EGR Cooler physically installed.
EGR Delete Kit for 2015-2016 Ford 6.7L Powerstroke Overview Removes the exhaust gas recirculation system, reduces carbon buildup, and improves airflow.
Upgrade Your 6.7 Powerstroke -
Full Removal Kits: Completely pull out the EGR valve, cooler, and associated piping.
EGR Delete Kit for 2015-2016 Ford 6.7L Powerstroke Overview Removes the exhaust gas recirculation system, reduces carbon buildup, and improves airflow.
Upgrade Your 6.7 Powerstroke
For a technical owner of a 2015 F-350, the decision should not be based on price or perceived simplicity, but on long-term reliability and the elimination of future coolant leaks. We dive into the critical differences and explain why one solution is fundamentally safer than the other.
1. Technical Deep Dive: The Hidden Coolant Leak Risk
The EGR cooler's primary function is to cool hot exhaust gases using the engine's coolant. Its most common failure mode is an internal leak, where the cooler fails and allows engine coolant to leak into the exhaust or intake manifold.
The Fatal Flaw of the Pass-Through Method
The biggest mistake often overlooked by customers choosing the Pass-Through method is that it does not eliminate the source of the leak.
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Gas Flow Blocked: Yes, the exhaust gas (EGR) flow is blocked off with plates.
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Coolant Still Circulates: Crucially, the coolant lines in a Pass-Through setup must continue to flow through the original EGR cooler to maintain the engine's overall thermal balance.
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The Risk Remains: Because the EGR cooler body is still sitting in the engine bay, cooling coolant, the internal welds, fins, and material can still degrade over time, leading to an internal coolant leak. You still face the possibility of expensive engine damage down the road.
Expert Verdict: For maximum reliability on your 2015 F-350, any kit that leaves the cooler installed carries an inherent, unnecessary risk.
2. Head-to-Head Comparison: Reliability vs. Compliance
Here is a mechanic's breakdown of the two methods, weighing long-term reliability against the perceived benefit of "visual compliance."
| Feature | Pass-Through Kit (Retain Look) | Full Removal Kit (Clean Sweep) | Reliability/Safety Score |
| Coolant Leak Risk | Moderate/High: The physical cooler remains, and thus the risk of internal coolant leakage remains active. | Zero: The primary failure point is physically removed from the engine's coolant circuit via a dedicated Coolant Bridge plug/pipe. | Full Removal Wins |
| Engine Bay Cleanliness | Poor. Components are still cluttering the engine bay. | Excellent. Creates significant space for easier future maintenance (e.g., turbo work). | Full Removal Wins |
| Installation Time | Faster. Primarily involves blocking plates and sensor relocation. | Slower/More Complex. Requires removing the bulky cooler and piping. | Pass-Through Wins |
| Visual Compliance (Stealth) | High. Looks stock at a glance. | Low. The gaping hole is easily noticeable upon close inspection. | Pass-Through Wins |
3. Beyond Aesthetics: Long-Term Maintenance & Cost
While the initial cost of a Pass-Through kit might be slightly lower, consider the long-term impact on your 2015 F-350 ownership:
A. Maintenance Obstruction
The EGR cooler assembly is bulky. Removing it (Full Removal) frees up a significant amount of space behind the engine. When the time comes for routine maintenance or repair—such as working on the turbocharger or the fuel system—the wide-open engine bay created by a Full Removal Kit saves hours of labor, making the initial investment pay off instantly.
B. The 2015 Specificity
The 2015+ 6.7L Powerstroke engine is a workhorse, but you should not compound its complexity. By choosing Full Removal, you are simplifying the engine's cooling system, which is a key factor in diesel reliability. The clean look and reduced component count are always better for a high-mileage work truck.
Final Recommendation
For any owner of a 2015 F-350 6.7L Powerstroke prioritizing ultimate reliability, reduced maintenance complexity, and the complete elimination of potential failure points:
Always choose the Full Removal Delete Kit.
While the Pass-Through kit offers a superficial level of stealth, the hidden risk of an internal EGR cooler coolant leak simply isn't worth the gamble on your expensive diesel engine. Simplify the system, remove the weakness, and enjoy true peace of mind.
Click Here to Shop Our Full Removal EGR Delete Kits and Coolant Bridge Packages for the 2011-2019 Powerstroke and maximize your truck's longevity!
