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2004 vision w/427 is running top tank completely dry after 1 day of work. There is no visual coolant leak. Driver even complains of power lose. Could this be a egr cooler issue?

It could be. With that amount of coolant loss you should be visually detect the leak by pulling the outlet hose off of the EGR cooler and having a look inside.

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"Mebbe I'm too ugly and stupid to give up!"

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