EGR Cooler Kit for International 3200 (2004-2006) 7.6L

Heavy-Duty Stainless Steel EGR Cooler Kit for 2004-2006 International 3200 (3000-Series Chassis)

What it Does: The EGR Cooler Kit drops recirculated exhaust gas thermal loads before re-entering the intake manifold on the 2004-2006 International 3200 to eliminate internal coolant consumption and prevent thermal runaway.

The Stock International 3200 Core Thermal Fatigue

Factory round EGR coolers installed on the DT466 7.6L platform suffer from severe thermal cycle fatigue. High-temperature soot-laden exhaust repeatedly expands the internal brazed cooling tubes, causing wall thinning and eventual micro-fracturing. Once ruptured, pressurized engine coolant bleeds directly into the exhaust tract or intake stream, producing heavy white exhaust smoke, rapid coolant loss without external puddling, elevated cylinder head temperatures, and recurrent EGR differential pressure trouble codes.

The Engineering Solution

Engineered to resolve heat-soak stress fractures, this direct-replacement 11.5-inch round cooler features high-grade TIG-welded stainless steel internal passages that resist thermal shock, sulfur pitting, and thermal cycling under sustained gross vehicle weight loads. The assembly restores proper heat transfer to lower intake charge temperatures without restricting exhaust mass flow. Direct interchange compatibility ensures exact mating with the factory turbo up-pipe and exhaust manifold plumbing, maintaining strict EPA04 emissions compliance while eliminating persistent coolant leakage.

What's Included

• 1 Stainless Steel Round EGR Cooler
• 1 Coolant Tube
• 1 Mounting Bracket Clamp
• 2 Hose Clamps
• 1 Exhaust Ring Gasket
• 1 Triangle Flange Gasket
• 3 O-Rings
• 3 Fastener Bolts

Technical Specifications

Compatibility

• 2004-2006 International 3200 Base Medium-Duty Cutaway/Chassis (7.6L L6 DT466 Diesel)

Frequently Asked Questions & Fitment Warnings

Does this fit the 3000-Series 3200?

Yes, this is a direct fit for the 2004-2006 International 3200 equipped with the DT466 7.6L engine. Verify your original unit is the 11.5-inch round-body cooler prior to installation.

Is a cooling system bleed required following installation?

Yes, the cooling system must be fully drained, refilled with proper heavy-duty extended life coolant, and purged of air pockets to prevent localized hot spots and premature cooler cracking.

The International Heavy-Duty Caliber

Commercial haul cycles demand structural reliability; this stainless cooler assembly handles high continuous exhaust gas temperatures to maintain cooling capacity under maximum payload and severe-duty route service.