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89-92 2.3 EGR tube fix


stuntsunltd.

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NE Texas
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1992
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Ford
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2.3L
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Manual
Anyone with a cracked EGR tube on their Gen2 with a 2.3 knows what a PITA it can be to find a replacement so here is my solution.

1. Locate break/crack/hole in tube
2. With a hand held hacksaw or reciprocating saw cut tube in center of break
3. Remove EGR tube at EGR valve
4. Slide a length of 9/16" silicone hose over the tube (down towards the exhaust manifold) to abt 1.5 to 2 inches past the break and secure with a rack and pinion type hose clamp.
5. Mock up the upper piece of the EGR tube to determine the length of hose needed to cover the break in it.
6. Cut the silicone hose to the needed length and insert the upper portion of the EGR tube
7. Re-install the EGR tube at the valve and secure upper portion of silicone hose in the same manner as the lower point.

**Note** This is a temporary and inexpensive fix if you need your EGR to pass an emissions related test. This will not last forever but I can replace the hose several times for the cost of buying a new EGR tube from the dealer.


Pictures to follow soon
 


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adsm08

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While that is a good idea, I have something to add.

It will be a more reliable fix if you flare the ends of the tubing slightly. That will reduce the risk of the hose coming off.
 


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