EGR Cooler Kit for International 8500 (2004-2009) 9.3L

Direct-Replacement EGR Cooler Kit for 2004-2009 International 8500 (NGV)

What it Does: The EGR Cooler Kit lowers recirculated exhaust gas thermal load before reintroduction into the intake tract on 2004-2009 International 8500 trucks to prevent overheating and maintain proper emissions operation.

The Stock International 8500 Cooler Fatigue & Rupture

Factory round-style EGR coolers running on the DT570 and HT570 platforms endure aggressive thermal cycling, soot accumulation, and coolant flow starvation under heavy vocational cycles. Over extended operating hours, internal stainless capillary tubes develop stress fractures along the brazed joints, venting pressurized engine coolant directly into the exhaust stream. This failure presents as mystery coolant consumption, thick white exhaust smoke, thermal de-rate conditions, and severe EGR delta-pressure fault codes that leave heavy-duty regional haulers sidelined.

The Engineering Solution

Engineered to restore factory thermal management, this 11.5-inch round-style cooler utilizes thick-wall, high-grade stainless steel construction built to resist acoustic pulsation and internal thermal fatigue. Precision TIG-welded end caps eliminate internal joint migration, while an unrestricted internal tube matrix optimizes heat transfer back into the engine's coolant circuit without excessive soot choking. Delivered as a comprehensive service kit, it includes an OE-spec coolant bypass tube, heavy-duty mounting bracket clamp, and high-temp fluoroelastomer O-rings to ensure a leak-free hydraulic seal under maximum manifold backpressure.

What's Included

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

Technical Specifications

Compatibility

• 2004-2007 International 8500 with HT570 / DT570 9.3L
• 2008-2009 International 8500 TranStar with DT570 9.3L

Frequently Asked Questions & Fitment Warnings

Does this fit the NGV 8500?

Yes, this is a direct fit for the 2004-2009 International 8500 equipped with the DT570 and HT570 9.3L engines; verify that your truck uses the 11.5-inch round cooler rather than a square heat exchanger before installation.

Do I need to bleed the cooling system after installing this EGR cooler?

Yes, the cooling system must be fully drained, refilled, and vacuum-bled to factory specifications to eliminate trapped air pockets that cause localized boiling and premature cooler failure.

The International Standard

Severe-duty regional hauling and high-idle vocational operations require cooling hardware built to survive relentless heat cycles without degrading payload uptime or towing endurance.