Why you need to replace OEM coolant overflow jug, spelab brings you a complete solution!
Currently we see too many forums and discussions from enthusiasts about coolant leaks, loose coolant cap seals, OEM overflow jugs creating swells and cracks, EGR cooler failures, and more. Don't wait until your truck has one of these problems to seek help! Upgrade your coolant reservoir ahead of time to avoid leaks that can lead to thousands of dollars in engine cleanup with your time!
Problems with OEM Coolant Reservoir jugs
The original design of plastic coolant jug, with the passage of time and driving kilometers, is very easy to appear the following problems:
material aging, material becomes brittle, thermal expansion and contraction lead to the jug body micro-cracks, fatigue deformation of the joints, sealing failure.
coolant overflow or leakage, once the plastic jug produces a small crack, the coolant will be under pressure to continuously leak, resulting in: overheating of the engine, dry burning of the EGR cooler, cleaning Problems.
SPELAB has developed a high-performance aluminum coolant jug, which is designed to solve the above problems:SPELAB Coolant Reservoir
| Feature | OEM Plastic Tank | SPELAB Aluminum Tank |
|---|---|---|
| Material | Molded plastic | welded aluminum |
| Heat resistance | Poor — softens over time | Excellent — holds up under heat |
| Finish | Faded, prone to discoloring | Black anodized, corrosion-proof |
| Longevity | High failure rate | Built to last |
| Appearance | Basic and dull | Clean, performance-style look |
What About the Missing Second Port?
You may notice that some years of OEM coolant reservoirs have two coolant line ports, such as the Ford 6.4L Powerstroke overflow jug. The SPELAB coolant reservoir has only one. Here's why:
The second port connects to the return line from the EGR cooler.
If the EGR system is deleted, this line is no longer needed - there is a risk of leakage from the second port.
That's why the SPELAB reservoir has a simplified, single-port design optimized for trucks equipped with an EGR delete system.
If you keep the OEM EGR system, that hose must be connected back to the cooling jug; we recommend that you make a combined connection with a Y-hose.
Do I Need to Pair It with an EGR Delete Kit?
Here’s a quick guide:
| Your Truck Setup | Recommended Solution |
|---|---|
| Running OEM EGR | Use a Y-split adapter or custom hose fitting |
| Already deleted EGR | ✔ Direct bolt-on with SPELAB coolant reservoir |
| Planning to delete EGR | ✔ Best to bundle with SPELAB EGR Delete Kit |
Pro Tip: The best setup is to run the SPELAB coolant reservoir + SPELAB EGR Delete Kit — simplified plumbing, fewer failure points, and improved reliability.
how much coolant should be in the reservoir
The aluminum Coolant Reservoir from spelab comes with its own coolant transparent viewing window or float viewing window.
The coolant in the transparent window can be filled up to 50-60%.
For the coolant float window, add coolant until the red ball floats.
Installation Tips
1.It is recommended to cooperate with a professional mechanic for disassembly and installation;
2.Ensure that the cooling system exhausts thoroughly to avoid falsely high water temperatures;
3.Check that the hose fittings are sealed securely after installation;
4.If EGR Delete is used, please match the tuning or close the EGR related DTC fault code.
Frequently Asked Questions (FAQ)
1. Why does the OEM coolant reservoir fail so often?
Due to constant heat cycling, the stock plastic water tank is prone to cracking and warping. Over time, this can lead to pressure leaks, coolant loss, and even engine overheating.
2. What makes the SPELAB coolant reservoir better than OEM?
SPELAB’s tank is built from aircraft-grade T6061 aluminum, TIG-welded for strength, and anodized for corrosion resistance. Unlike plastic, it won’t crack, discolor, or leak under heat and pressure.
3. Can I use the SPELAB coolant reservoir with a stock EGR system?
Yes, but you'll need to route the second return hose using a Y-hose adapter or modify the line to prevent leakage. For best results, we recommend pairing with the SPELAB EGR Delete Kit.
4. Do I need to tune the truck after installing the coolant reservoir?
No, installing the coolant reservoir alone doesn’t require a tune. However, if you’re pairing it with an EGR delete kit, a tune is required to avoid CEL (Check Engine Light) and to ensure proper system operation.
5. How much coolant should I add to the new tank?
When cold, fill the coolant to about 50–60% of the tank’s capacity. Always bleed air from the system after filling. Do not overfill — coolant expands as the engine warms up.
Final Thoughts: Stop Leaks Before They Start
The factory plastic coolant reservoir will fail — it’s just a matter of when. With the SPELAB aluminum tank, you’re not just replacing a part — you’re upgrading your truck’s entire cooling system.
Whether you’re solving an existing leak or building a bulletproof Powerstroke, SPELAB’s coolant reservoir is your go-to solution.
"Plastic cracks. Aluminum doesn’t lie."
