1999 Ranger EGR removal...ideas?


1999Mazda Central Florida

5+ Year Member

U.S. Military - Veteran
Joined
Jan 26, 2017
Messages
53
Points
601
Vehicle Year
1999
Engine
2.3 (4 Cylinder)
Transmission
Manual
Tire Size
Michelin LTX M/S P235-75R15
On the '99 Ranger (or MazdaB2500) the EGR is way behind between firewall and manifold. I removed the manifold for other reasons and decided to change EGR at same time. The 27mm hex that holds EGR pipe to EGR itself is so rusted on I can't get it off. It's been soaking in PB blaster and I tried a pipe wrench for grip but it's really rusted on. Now the pipe is loose in the bolt (sort of like a brake line set up) and I may actually need to replace the whole pipe that leads to exhaust. Any ideas on that hard to reach EGR removal? Next step may be to cut the EGR tube and use socket on nut that holds EGR tube into Exhaust port (using a breaker bar to get that nut off after tube is cut.) Then I'll need a new EGR tube $$$$$
Much appreciated suggestions...This whole job started out as simply trying to replace my TPS and devolved into a circus of other problems and mishaps.
 

Attachments

  • 1999 Ranger EGR removal...ideas?
    Rusted 27mm nut holding EGR onto EGR pipe.jpg
    85.5 KB · Views: 3
Torch. And not a little propane job either, you need a LOT of heat. That thing has been heat cycled so many times and when you add in rust and that it probably wasn’t assembled with any anti-seize (high temp copper is the ticket with exhaust stuff), it becomes a headache.

I’m not sure if the tube is still available, might want to check on that if you haven’t.

Seems to me like the EGR system could have been designed to be more serviceable
 
Thanks for reply Lil Blue, I got tube out. The bottom nut is easier to reach with everything out of the way. Just took the whole tube out and looks to be in good shape. Cleaned up threads and will use anti-seize (don't have high temp copper<--thanks for that advice too.) Yes, agree, not very serviceable. I'm going to change sparks plugs while I have intake manifold off.
Hope this will all go back together ok and won't have to write a post on this.
 

Attachments

  • 1999 Ranger EGR removal...ideas?
    EGR from afar.jpg
    103.4 KB · Views: 0
  • 1999 Ranger EGR removal...ideas?
    EGR from top closer.jpg
    84.2 KB · Views: 0
  • 1999 Ranger EGR removal...ideas?
    EGR tube bottom view.jpg
    78.3 KB · Views: 0
  • 1999 Ranger EGR removal...ideas?
    Tube in vise.jpg
    145.3 KB · Views: 0
  • 1999 Ranger EGR removal...ideas?
    In vise close.jpg
    118.9 KB · Views: 0
  • 1999 Ranger EGR removal...ideas?
    EGR off.jpg
    168.6 KB · Views: 0

Sponsored Ad

TRS Events & Gatherings

Featured Rangers

Want to see your truck here? Share your photos and details in the forum.

TRS Latest Video

Official TRS Merchandise

Follow TRS On Instagram


Product Suggestions

Back
Top