Aluminum Coolant Overflow Expansion Tank for Ford F250 F350 (2003-2007) 6.0L Engine

Eliminate the weakest link in your cooling system before that brittle factory plastic leaves you stranded on the side of the highway with a steam cloud.

Aluminum Coolant Overflow Expansion Tank for Ford F-250/F-350 Super Duty & Excursion

If you drive a 2003-2007 Super Duty, particularly the 6.0L Powerstroke, you know the "Degas Bottle" struggle. The factory reservoir is made of molded plastic that sits right in the hottest part of the engine bay. Over years of thermal cycling—going from freezing cold to 200°F+ while towing—that plastic turns yellow, becomes brittle, and inevitably develops hairline cracks. For 6.0L owners, high cooling system pressures (often a symptom of the EGR cooler or head gasket issues) can split a factory tank at the seams or strip the plastic cap threads, causing the dreaded coolant "puke."

This Aerospace Grade AA5052 Aluminum expansion tank is the permanent solution to the plastic problem. Unlike the stock unit, aluminum doesn't fatigue from heat cycles or UV exposure. It is fully TIG welded for maximum structural integrity, allowing it to withstand higher internal pressures without ballooning or bursting. We’ve replaced the opaque plastic with a robust metal design that actually dresses up the engine bay, replacing that ugly, yellowed eyesore with a clean Silver Anodized finish.

One of the biggest complaints about switching to an aluminum tank is losing the ability to check coolant levels quickly. We solved that by integrating a heavy-duty sight glass directly into the side of the unit. You get the durability of metal with the convenience of a factory tank. Whether you are running a stock 5.4L Triton or a tuned 6.0L Powerstroke pushing serious boost, this tank bolts directly into the factory location using existing mounts, ensuring your cooling system stays sealed and efficient.

Why You Need This Upgrade

• Aerospace Grade AA5052 Aluminum: Superior resistance to heat and corrosion compared to standard alloys, ensuring the tank survives the harsh under-hood environment.
• Integrated Sight Glass: Allows for instant visual verification of coolant levels without opening the cap and introducing air into the system.
• Fully TIG Welded Construction: Provides a leak-proof seal and structural rigidity that molded plastic tanks simply cannot match.
• Pressure Tested Reliability: Every unit is pressure tested to ensure it can handle the thermal expansion and contraction of heavy-duty towing.
• Direct Bolt-On Fitment: Designed to match OEM mounting points and hose locations for a hassle-free installation with no cutting or drilling.

Installation Notes

Installation is straightforward but requires handling engine coolant. You will need to siphon or drain the coolant from the existing tank below the return hose level before removal to avoid a mess. Be careful with the small return line nipples on the radiator side, as old plastic fittings can be brittle. We recommend inspecting your radiator hoses and the degas bottle cap while you are in there; a fresh cap is cheap insurance for your new aluminum tank setup.

Replaces These OEM Applications & Part Numbers

• 2003 - 2007 Ford F-250 6.0L V8 Powerstroke
• 2003 - 2007 Ford F-350 6.0L V8 Powerstroke
• 2003 - 2005 Ford Excursion 6.0L V8 Powerstroke
• 2007 Ford F-250 Super Duty 6.0L
• 2007 Ford F-250 Super Duty 5.4L
• 2007 Ford F-250 Super Duty 6.8L
• 2007 Ford F-350 Super Duty 6.0L
• 2007 Ford F-350 Super Duty 5.4L
• 2007 Ford F-350 Super Duty 6.8L
• 2006 Ford F-250 Super Duty 6.0L
• 2006 Ford F-250 Super Duty 5.4L
• 2006 Ford F-250 Super Duty 6.8L
• 2006 Ford F-350 Super Duty 6.0L
• 2006 Ford F-350 Super Duty 5.4L
• 2006 Ford F-350 Super Duty 6.8L
• 2005 Ford Excursion 6.0L
• 2005 Ford F-250 Super Duty 6.0L
• 2005 Ford F-250 Super Duty 6.8L
• 2005 Ford F-250 Super Duty 5.4L
• 2005 Ford F-350 Super Duty 6.0L
• 2005 Ford F-350 Super Duty 6.8L
• 2005 Ford F-350 Super Duty 5.4L
• 2004 Ford Excursion 6.0L
• 2004 Ford F-250 Super Duty 6.0L
• 2004 Ford F-350 Super Duty 6.0L
• 2003 Ford Excursion 6.0L
• 2003 Ford F-250 Super Duty 6.0L
• 2003 Ford F-350 Super Duty 6.0L

Stop waiting for the plastic to fail—upgrade to aluminum durability and keep your Super Duty on the road where it belongs.