Rusty EGR?

[ghack]

I have a 95 Ranger. I'm not sure what the part is called, but there is a diaphragm attached to a smaller pipe off the exhaust manifold that is leaking like a sieve. The whole thing is very rusty, and looks like it rusted thru. What is that part called, and any tips for replacing it? The bolts are so badly rusted, i don't think they'll come out in one piece.

 

[Mark_88]

Probably the EGR...they do tend to rust but usually come off...just use the right wrench and try it when it is cold first...if they are tight then run the engine a bit to warm it up and then shut it off and apply some PB Blaster or similar...let it cool (don't inhale the fumes from the lubricant) and try again.

Worst case scenario is they break...then you may have to remove the throttle body and either drill them out or simply replace the whole throttle body...

You can also try capping it at the exhaust side while you are dealing with the upper end but make sure you cap the upper side if you plan to drive it as the EGR will suck in fresh air causing a possible lean condition which is not a good thing typically.

Replacing the pipe might be a harder thing to do unless you can grab one from a junkyard or make one up (or have someone else do that).

 

[NEVERDONE86]

I used copper tube from the hardware store. Reused the same fittings but it worked like a champ.

 

[Mark_88]

I tried copper sections and it worked out pretty good, but the end on the exhaust flange got kinda singed...and started to deform a bit...after about three years.

I thought copper had a higher melt point but maybe my exhaust just runs a bit hotter than it should.

 

[Destroyer000]

this is pretty common on the 4.0s. if you go to your dealer they can get you the upper and lower egr tube would cost about 140 for them and an egr valve can be bought from any parts store for bout 50-70. ebay has upper tubes for 45 bucks.

 

[ghack]

follow up

Thanks for comments and suggestions. It could be all the rust, but it looks like the nut on the tube going into the EGR is star-shaped and not flat sided. I almost think the star-shape is part of the end of the EGR valve and spins onto the pipe. It doesn't make sense, but that's what it looks like. The sides of the nut are curved-in between the points, like a gear, and I can't see any break between that nut and the EGR. I did soak it with PB, ran the engine and soaked it again. I also did the other end of the tube in case i have to pull the whole thing off. I'll let it sit today, then soak and try again. If that doesn't work, then I'll try heating a little with the torch. The bolts connecting the valve to the upper tube are stuck also. One bolt is 10mm, the other I could put an 8mm on. Again, it might be all the rust, or someone changed something previously.