EGR Cooler Kit for International 7300 (2004-2006) 7.6L

Heavy-Duty Stainless Steel EGR Cooler Kit for 2004-2006 International 7300 (WorkStar Medium Duty)

What it Does: The EGR Cooler Kit lowers the temperature of recirculated exhaust gas before reintroduction into the intake stream on 2004-2006 International 7300 trucks to prevent thermal overload and maintain factory emissions compliance.

The Stock International 7300 EGR Thermal Fatigue Failure

Factory round EGR coolers installed on the Navistar DT466 platform suffer chronic thermal cycling breakdown. Prolonged exposure to high-temperature exhaust gas creates intense thermal stress between the internal coolant channels and exhaust tubes. Over operational hours, microscopic stress fractures develop across thin-wall internal core welds, leading to internal coolant loss into the exhaust stream, persistent white smoke, uncommanded cooling system pressurization, elevated cylinder head temperatures, and recurrent EGR differential pressure trouble codes.

The Engineering Solution

This replacement EGR cooler is engineered with heavy-gauge, corrosion-resistant stainless steel construction to withstand severe thermal expansion without core degradation. Measuring approximately 11.5 inches in length with an OEM-spec round profile, the TIG-welded assembly maintains uniform heat dissipation across internal gas passages to drop exhaust gas recirculation temperatures reliably. The direct-fit design matches factory mounting locations precisely and includes a dedicated coolant tube, support bracket, and a full set of high-durometer O-rings and composite flange gaskets to eliminate leak points during high-load vocational operation.

What's Included

• 1 EGR Cooler (Round Style, Stainless Steel, approx. 11.5 in)
• 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 International 7300 Base Medium-Duty Vocational Truck (7.6L DT466 Turbo Diesel)
• 2005 International 7300 Base Medium-Duty Vocational Truck (7.6L DT466 Turbo Diesel)
• 2006 International 7300 Base Medium-Duty Vocational Truck (7.6L DT466 Turbo Diesel)

Frequently Asked Questions & Fitment Warnings

Does this fit the WorkStar Medium Duty 7300?

Yes, this is a direct fit for the 2004-2006 International 7300 equipped with the DT466 7.6L inline-six diesel engine using the 11.5-inch round-style core; always verify your stamped OEM casting number prior to ordering.

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

Yes, technicians must completely drain, flush, refill, and purge trapped air from the cooling system to prevent localized hot spots that can crack new cooler cores and cylinder heads.

The International WorkStar Standard

Engineered for high-GVWR commercial applications, severe-duty dump cycles, and heavy municipal hauling, this stainless replacement assembly restores thermal equilibrium to keep your vocational fleet moving without unscheduled downtime or costly cylinder head overheating.