egr replacement. please read!

[strtspdlx]

well...my egr valve broke so i have to replace it. unfortunately the egr tube nut is rusted so bad i also have to replace that...and even more unfortunate its rusted to the manifold so i have to replace that also. does anyone know were to get these parts and if the bolts for the manifold are a pita or should it go over with no problem. the vehicle is a 1995 ford ranger 4.0 5spd 4wd. thanks

 

[CraigK]

Here's what I did when my EGR tube rusted away. On a 20+ year old vehicle, I could not justify the expense of a complete remove and replace repair.

I used a pipe-thread pipe cap (local hardware store, <$1) and some metal epoxy to cap and seal the rusted/destroyed inlet port on the exhaust manifold (might want to use exhaust cement for this). I also removed the EGR outlet tube, cut it off with about a 2" section left at the EGR valve end, and flattened it out and curled it up (it seemed to be soft copper) to seal that end, and screwed it back on. I capped and plugged all of the EGR related vaccuum lines (set of plastic caps from AutoZone, <$5). Result - No more EGR issues.

If your EGR outlet thread is trashed, you might want to remove the whole EGR assembly, and use a flat piece of steel to simply block off the whole port.

For those who are going to say that this will cause poor engine performance, I can only say that my '87 BII runs very well. For years now. Additionally, although my BII is now registered as "Historic", and exhaust emissions testing and compliance is no longer needed, before this, the vehicle passed MD emissions testing with flying colors with this set-up (EGR disconnected)!

CraigK

 

[ZMan]

I don't know if you can do this on a 1995 4.0 or not. But on a '94 3.0l I just got a block off plate for the intake manifold that came off of a non-egr vehicle...then welded up the hole in the exhaust manifold.

 

[strtspdlx]

ill have to look into that. im pretty sure it will set a cel which im trying to avoid. does anyone know were i could purchase an egr tube? im having trouble finding one.

 

[94b4kzoomzoom]

i have a question as well. Im going through the same situation. only my manifolds are shot so I went to the junk yard and got them from a 97 4.0l in good condition. but the egr nipple on the manifold is on the other side. i would have to add pipe. if i was to block both off will it make the check engine light go on?

 

[Yellowsplash]

The only person who carries the egr tube is the dealer...

 

[BRUTUS_T_HOG]

junk yard is usually the only option.

i've been able to get a new one for an 89 f150 and an 89 tbird so who knows