2002 Mazda B4000 EGR Tube disconnected from Exhaust Manifold

[kiallowski]

Hello folks,

I just bought my first used truck which is a Mazda B4000 (basically a Ford Ranger), V6, 4.0L, 4x4. I recently brought it to the Muffler shop, where they put in brand new Catalytic Converters (which I bought on Rock Auto) and a new Muffler system, which they provided. Not a cheap fix, but It has been worth it and is not as loud as it was when I bought it anymore. They said that everything else on the truck is in good shape, minus the EGR Tube/Valve/Manifold. I knew I was going to have to put money into it. You kind of have to with old trucks.

Anyway, they showed me that the original EGR Tube was disconnected from the original Exhaust Manifold and they gave me all the parts numbers for the EGR Tube, EGR Valve and Exhaust Manifold. I found all of the parts on Rock Auto for a reasonable price, and I'm still shopping around.

I live in NYS so I need the EGR system to work in order to pass emissions.


The mechanics said that I could buy just the EGR Tube and they could try to get it back onto the original Exhaust Manifold, but didn't guarantee that that would fix the problem with the disconnected EGR Tube because the tube and valve is worn out (because it is the original). They do Exhaust Manifold work and on their website they say this:

Exhaust Manifolds:

"Exhaust Manifold replacement is a large part of our business. Whether your manifold is cracked, corroded, or the bolts that hold the manifold to the head have broken causing that annoying ticking sound we can fix these issues. We have the ability to remove broken bolts from the head on the engine without major engine work. This is a process we have mastered over the years. If parts are unavailable for your car or truck. We repair most manifolds by either welding them or having the warped mating surface machined to be perfectly flat again and reused."


Now, I'm debating on whether I should just start by buying the EGR Tube and see what they can do like they said. Or would it just make sense in the long run to buy all three of the required new parts (EGR Tube, EGR Valve and the Exhaust Manifold) and have them install it?

Do you think I will be able to get away with just a new EGR Tube and Valve attached to the original Exhaust Manifold? I'm leaning more towards buying all three of the parts, because the existing parts are all original and corroded, but I want to see other opinions. The parts aren't that expensive too which is good. Only bad thing is paying for labor.

Also, will a new EGR Tube, EGR Valve and Exhaust Manifold make the truck sound quieter? What will it help with besides emissions and combustion?

Will I be able to drive long and short distances with it broken?

Thank you for any input!

 

[Colin]

Unfortunately I think you'll have to purchase all 3, that looks super crusty and the odds of it coming apart nicely are low. Pretty likely that the manifold studs will break as well so you should get those and new nuts as well

 

[kiallowski]

Thanks for the reply... The the EGR valve isn't crusty like the EGR Tube and Exhaust Manifold, but maybe I should buy it anyway. I can always return it on Rock Auto. I'll probably just buy all three parts then.

This Dorman Exhaust Manifold that the Mechanics told me to get comes with 2 studs. Where can I find the correct nuts?

SO installing a new Exhaust Manifold, EGR Tube and EGR Valve is very doable then? I probably shouldn't be worried that it won't work out then? Like I said, this muffler shop does do Exhaust Manifold work. I feel like thy wouldn't tell me to get these parts, and calling up auto parts stores for me if it wasn't possible, right? The Exhaust Manifold is a common part that a lot of places are capable of doing, right?


Here is the part I'd be buying:

More Information for DORMAN 674706 (rockauto.com)

 

[sgtsandman]

I’m wondering why they are making you so all the leg work to get this fixed. Any shop I’ve ever dealt with did all the parts look up and ordering.

I would make the assumption right off the bat that all the faster hardware is going to need replaced. You or they may need to go through a dealer for the hardware. That is what I had to do to replace the studs connecting my exhaust manifold to the catalytic converter. The studs came with the nuts, if I remember correctly.

 

[kiallowski]

It's because they called some local parts stores, and so did I and not many places like advance or napa have them right now, so Rock Auto it is. I can buy the nuts though, unless the shop has them which I would think thy do?... What type of nuts should I buy? Dorman specific?

Here's the EM part:

More Information for DORMAN 674706 (rockauto.com)

thanks again!

 

[sgtsandman]

That should work but I would bet on all the hardware mounting the manifold to the block being an issue and order them if the garage doesn’t have them. Better to have the hardware and not need than need the hardware and not have it. As far as the nuts, check the repair center. If they have them, great. If not, Dorman or whatever should do the job. They are all going to get rusty.

Check to make sure they have or can get the needed gaskets too. I see the manifold comes with one for the block. You may need one from the manifold to the pipe. Mine are the donut style. Yours probably are as well.

 

[kiallowski]

Unfortunately I think you'll have to purchase all 3, that looks super crusty and the odds of it coming apart nicely are low. Pretty likely that the manifold studs will break as well so you should get those and new nuts as well

I have another concern! Will it be fairly “easy” for the mechanics to take off the old exhaust manifold and install the new one without having to disconnect other parts around the EGR System? Like the engine. I’ve read, at least for other cars and trucks that mechanics have to drop the engine and stuff to install a new Exhaust Manifold. I was looking from the top of the engine and underneath where the EM is connected to the Catalytic Converter, and saw where they could could work through some openings. I’m sure with extra long tools, they could be able to maneuver around and install the new manifold after a few hours hopefully. Any thoughts?

Also, will these nuts and studs fit the Exhaust Manifold I bought?

More Information for FEL-PRO ES75118

 

[Dirtman]

If it's going to a shop let them get the parts...

 

[kiallowski]

If it's going to a shop let them get the parts...

what parts? Like the nuts and studs I posted? I bought the EGR Tube and Exh Manifold on Rock Auto for cheaper than what the shop could find.

 

[Dirtman]

Good mechanics are rarely happy with customers bringing their own parts, most won't even work on the vehicle unless they purchase the parts.

 

[kiallowski]

I’ve done it before, they literally told me the parts numbers and were happy to give them to me. Depends on the shop