How do you remove the EGR tube from the exhuast manifold?

Answer 1

I had to remove the fan, shroud, serpentine belt, alternator, belt tensioner and smog pump to get access to the EGR tube fitting where it screws into the front of the passenger side exhaust manifold. The reason for removing the aforementioned components is due to the bracket that bolts to the front of the block that they attach to is in the way as well as the smog pump and hoses. It is an all day job, and you need to be patient and have a good 3/8 pneumatic ratchet and shop air available. I have a 1991 F-250 with a 5.8 and went through this exercise recently. Access to the fitting at the manifold is extremely tight.

Good Luck!

First, you did not mention why you had to remove the tube. Was it leaking because of the weld amidship were broken or leaking, etc. I just replaced my EGR tube/line last week and what I did after studying the situation and getting a good look at the way my 1992 Ford F250 with the 5.8L FI engine setup, I decided to purchase a small open end hacksaw handle with a good blade that stuck out the front at least 6 inches. I found such a saw at my local Lowes store. Now, all you really have to do is unbolt several fasteners that hold the metal tubes that run right above the spark plug wires, and unfasten the number one plug wire, the one on the right side of the engine. This is so you won't break the plug when you start sawing the end of the tube that goes into the exhaust manifold. You will notice that the tube is held on with a large nut (1 and 1/4 inch in size) and another piece that is screwed into the exhaust manifold. Don't worry about that part right now because is will come out by itself with the frozen nut. Spray the heck to the adapter I just mentioned with CRC Parts Freeze Off you can buy at your local Pep Boys or any Parts Store. Let it sit on the frozen nut and coupler that are attached to the exhaust manifold for at least one hour. Then you can cut the pipe off as close to the 11/4 inch nut as possible. After you have done that, get a 1and 1/4" socket and a 1/2" extension for your 1/2 ratchet and remove the frozen 2 inches of nut and coupler off the exhaust manifold. Before installed the new EGR Tube, try to clean as much of the threads that go into the exhaust with a small round wire brush. This assuming that you are having to remove the EGR. To install the new one, just screw the coupler into the exhaust manifold first, tighten it with the round end of the 1 and 1/4 wrench and then install the 90 degree tube end into the adapter/coupler and don't tighten the tube nut all the way yet. Next attach the nut to the EGR Vale finger tight. Align the two ends and tighten the bottom nut first until it is snug. Next, tighten the nut that screws into the EGR valve snugly. Once you are satisfied that they are in alignment, tighten the bottom nut tightly until it won't turn anymore. next tighten the nut on the EGR Valve. This will frustrate a little, but you won't have to remove anything but the EGR Tube. You will need a 1/2 inch by 8 or 10 inches in length to reach the frozen nut. Good luck and let me know how things turned out.