Trying to get it right-

**Turdle** · 09-30-2007, 10:34 AM

Well it looks like the best thing to do would be to start a new egr tube-the hole at yellow arrrow is huge--
Eric (techieman33) was very kind and left me an extra tube-

If you look where the red arrow points you'll see a larger tube used as a sleeve-
I'm gonna cut it off and try to get the opening cleaned out to accept the new tube-then weld up around it-
As you can see I have the upper neck angle bent in pretty well--

Black lines show where I plan to cut--sound good?

Then I'll need to cut the extra tube off and weld that hole shut-which is what started this whole mess-
My egr tube was "working fine" even though it had an extra capped off tube sticking out-I should have left it ugly--

**Turdle** · 09-30-2007, 01:36 PM

OK
DPFE
Differential Pressure Feedback EGR

From my experimenting and reading--
The DPFE sensor is merely that-a differential sensor-

there are 2 tubes on the egr tube going to it, in between each of these tube "nozzles" on the egr tube is an orifice--
it is a thick metal bushing with a small hole. this causes a pressure difference between the 2 "nozzles" when the exhaust gasses pulse through.
To satisfy the DPFE sensor-all that is needed is a differential between the 2 nozzles.
If you look at the new duplicated setup, which was working just fine on my truck-you'll see I used 2 egr tubes to make one-and in doing so I now have 2 orifices an 3 "nozzles"--lol
laugh now for a bit--

ok now-get over it for a minute and try to listen-
This is needed to connect to my Typhoon intake manifold-
I"M KEEPING MY EGR!!!
I had the tubes connected in every combination imaginable-with the extra "capped off " with a small chunk of silicone hose and a bolt in it.

As long as there is a pressure difference between the 2 hoses-all is good--No CEL

Don---any clues from this?

Back to the fix--

After debating about cutting this fine 100.00 egr tube---
and nobody to say no,
I turned to my buddy Mr Sawzall--

Here is where I am now-I had to sand the heck out of the inside of larger tube and outside of the egr tube-take my word for it it is slid in about 1/2" and is tight-I may need to adjust the length a bit though.
The bottom weld was wire welded by the exhaust shop I use-I think I'll go back there tomorrow and have him weld it up for me again. It is just a small exhaust pipe--you know.

Taking off the 3rd tube started all this mess--
I will use the top 2 for functions-and cap off the lower one. You'll never see it.

*CDW6212R* · 09-30-2007, 01:44 PM

Interesting, how large is that orifice hole? Obviously not much gets through it yes?

Very little is seen of the old EGR system, what is the big improvement with this odd tube design? The older system may be better for odd high performance combinations ie; ours.

**Turdle** · 09-30-2007, 01:51 PM

Quote:

Originally Posted by CDW6212R

Interesting, how large is that orifice hole? Obviously not much gets through it yes?

Very little is seen of the old EGR system, what is the big improvement with this odd tube design? The older system may be better for odd high performance combinations ie; ours.

The orifice passage is about 5/16" to 3/8" .

I like this system better actually-it is all external, and is less "mechanical" in that it doesn't use a "position " sensor and a linkage that must actually change position, and even if those mechanical actions occur-there could be a weak egr pulse.
This system actually senses egr pulses-and is much simpler--to me anyway.

*CDW6212R* · 09-30-2007, 01:57 PM

Okay then, you are telling me to make room for a weird pipe on my headers later. Thanks,

**Turdle** · 09-30-2007, 02:00 PM

Here is the orifice-just for understanding--

*CDW6212R* · 09-30-2007, 02:05 PM

That will flow plenty of air. I see custom unit like that in my future, cut and welded together to fit. Thanks for the example.

*Jakee* · 09-30-2007, 02:12 PM

This EGR tube is the most expensive and has the most hours to make; EGR tube I've ever laid eyes on.

**Turdle** · 09-30-2007, 03:13 PM

Quote:

Originally Posted by Jakee

This EGR tube is the most expensive and has the most hours to make; EGR tube I've ever laid eyes on.

One of a kind!

*techieman33* · 09-30-2007, 03:31 PM

Quote:

Originally Posted by jtsmith

One of a kind!

Glad to see you made use of my egr, otherwise it probably would have sat around doing nothing.

*rocket 5979* · 09-30-2007, 03:36 PM

Jon, I assume that you are going to make that throttle cable bracket yourself instead of sending your TB to me? Good luck with it.

**Turdle** · 09-30-2007, 05:03 PM

Quote:

Originally Posted by rocket 5979

Jon, I assume that you are going to make that throttle cable bracket yourself instead of sending your TB to me? Good luck with it.

I am probably going to end up sending it to you, But I want to give it one more crack--

**Turdle** · 10-01-2007, 03:27 PM

My Son Bryan is home for awhile-so we are doing some much needed fixes to his car-one of which was a new muffler. While there-I had the guy cut off the extra nozzle-and weld up the EGR tube.
I'll be back to this-but for now I'm doing the "dad" thing for a day or 2.

Xan · 10-01-2007, 06:02 PM

Quote:

Originally Posted by jtsmith

My Son Bryan is home for awhile-so we are doing some much needed fixes to his car-one of which was a new muffler. While there-I had the guy cut off the extra nozzle-and weld up the EGR tube.
I'll be back to this-but for now I'm doing the "dad" thing for a day or 2.

Shouldn't he take after his dad and be able to fix anything too?

Nice way to sneak in still working on your stuff

410Fortune · 10-02-2007, 10:19 AM

$100 for an EGR tube? Holy moley!!

running yet?

**Turdle** · 10-02-2007, 11:53 AM

Not Fair!!! You have help--good help

I'm on project Tempo-Bryan has my Grandmother's 91 Tempo with 40k on the clock--but it needs some attention.
So far we have replaced the valve cover gasket and grommets-new muffler (Grandma had installed a lifetime muffler-but she's dead now and it fell off), new tires, oil change, radiator flush,fuel filter and spark plugs.
Now we are cutting holes in the doors for his speakers. It will need some wooden spacers to clear the windows-so this will take the rest of the day.
We are also installing a head unit I got from Dan, plus an amp and subwoofer. Nothing great-but he'll have some better than stock sound.
He's looking for a nicer car-but this will be his daily beater.

The brakes squeak-so we need to look them over.
Then we are sanding the peeling window pillar trims and painting them black again, and a day is planned to go to the junk yard for some wheel center caps-

The Mounty is on hold for a minute.

Xan · 10-02-2007, 12:58 PM

Quote:

Originally Posted by jtsmith

Not Fair!!! You have help--good help

I'm on project Tempo-Bryan has my Grandmother's 91 Tempo with 40k on the clock--but it needs some attention.
So far we have replaced the valve cover gasket and grommets-new muffler (Grandma had installed a lifetime muffler-but she's dead now and it fell off), new tires, oil change, radiator flush,fuel filter and spark plugs.
Now we are cutting holes in the doors for his speakers. It will need some wooden spacers to clear the windows-so this will take the rest of the day.
We are also installing a head unit I got from Dan, plus an amp and subwoofer. Nothing great-but he'll have some better than stock sound.
He's looking for a nicer car-but this will be his daily beater.

The brakes squeak-so we need to look them over.
Then we are sanding the peeling window pillar trims and painting them black again, and a day is planned to go to the junk yard for some wheel center caps-

The Mounty is on hold for a minute.

Only 40k on the car? it can't be in that bad of shape its still a tempo not a chick magnet but it sounds like a ok car for a while. Let me know if you need any more stereo stuff i got alot laying around

**Turdle** · 10-02-2007, 01:01 PM

Quote:

Originally Posted by Xan

Only 40k on the car? it can't be in that bad of shape its still a tempo not a chick magnet but it sounds like a ok car for a while. Let me know if you need any more stereo stuff i got alot laying around

Hmm, what you got?

chriswells78 · 10-02-2007, 01:01 PM

I need a car like that to make into a mini-stock race car for my local track. LOL

Xan · 10-02-2007, 03:28 PM

Quote:

Originally Posted by jtsmith

Hmm, what you got?

I got a infinty kappa perfect 10" (hmm i might swap this back out) its in a box made for the mounty so the bigger of the fold down seat folds.
If i swap that back in i'll have 2 12" bosten G2s in a double box
I got a kicker comp vr8
and a pair of cerwin vega 6 1/2"s

i got the factory amp and sub out of the mounty

haha

09-30-2007, 10:34 AM	#161
Turdle Old and in the way Humboldt, Kansas 2000 Mounty Join Date: Jun 2003 Posts: 23,787 Vehicle Specs (Original Poster)	Well it looks like the best thing to do would be to start a new egr tube-the hole at yellow arrrow is huge-- Eric (techieman33) was very kind and left me an extra tube- If you look where the red arrow points you'll see a larger tube used as a sleeve- I'm gonna cut it off and try to get the opening cleaned out to accept the new tube-then weld up around it- As you can see I have the upper neck angle bent in pretty well-- Black lines show where I plan to cut--sound good? Then I'll need to cut the extra tube off and weld that hole shut-which is what started this whole mess- My egr tube was "working fine" even though it had an extra capped off tube sticking out-I should have left it ugly-- Attached Images __________________ Jon 2000 Mountaineer Turdle-gone Vitamin D Wagon Sold also

09-30-2007, 01:36 PM	#162
Turdle Old and in the way Humboldt, Kansas 2000 Mounty Join Date: Jun 2003 Posts: 23,787 Vehicle Specs (Original Poster)	OK DPFE Differential Pressure Feedback EGR From my experimenting and reading-- The DPFE sensor is merely that-a differential sensor- there are 2 tubes on the egr tube going to it, in between each of these tube "nozzles" on the egr tube is an orifice-- it is a thick metal bushing with a small hole. this causes a pressure difference between the 2 "nozzles" when the exhaust gasses pulse through. To satisfy the DPFE sensor-all that is needed is a differential between the 2 nozzles. If you look at the new duplicated setup, which was working just fine on my truck-you'll see I used 2 egr tubes to make one-and in doing so I now have 2 orifices an 3 "nozzles"--lol laugh now for a bit-- ok now-get over it for a minute and try to listen- This is needed to connect to my Typhoon intake manifold- I"M KEEPING MY EGR!!! I had the tubes connected in every combination imaginable-with the extra "capped off " with a small chunk of silicone hose and a bolt in it. As long as there is a pressure difference between the 2 hoses-all is good--No CEL Don---any clues from this? Back to the fix-- After debating about cutting this fine 100.00 egr tube--- and nobody to say no, I turned to my buddy Mr Sawzall-- Here is where I am now-I had to sand the heck out of the inside of larger tube and outside of the egr tube-take my word for it it is slid in about 1/2" and is tight-I may need to adjust the length a bit though. The bottom weld was wire welded by the exhaust shop I use-I think I'll go back there tomorrow and have him weld it up for me again. It is just a small exhaust pipe--you know. Taking off the 3rd tube started all this mess-- I will use the top 2 for functions-and cap off the lower one. You'll never see it. Attached Images __________________ Jon 2000 Mountaineer Turdle-gone Vitamin D Wagon Sold also Last edited by Turdle; 09-30-2007 at 05:09 PM.

09-30-2007, 01:44 PM	#163
CDW6212R Elite Explorer Knoxville, TN 98 Mountaineer A4WD Join Date: Jun 2004 Posts: 13,016 Vehicle Specs	Interesting, how large is that orifice hole? Obviously not much gets through it yes? Very little is seen of the old EGR system, what is the big improvement with this odd tube design? The older system may be better for odd high performance combinations ie; ours. __________________ Don 91 Lincoln LSC/SE, 99/93 Explorer Limited 4WD, 98 AWD Mounty with 255/55/18's, big sway bars, and 12.75" x 1.25" rotors. Soon a BW4406, built trans, stereo and interior. The best thing that could help us all, is the Fair Tax Plan. Be American, Buy American (Manufacturer)

09-30-2007, 01:57 PM	#165
CDW6212R Elite Explorer Knoxville, TN 98 Mountaineer A4WD Join Date: Jun 2004 Posts: 13,016 Vehicle Specs	Okay then, you are telling me to make room for a weird pipe on my headers later. Thanks, __________________ Don 91 Lincoln LSC/SE, 99/93 Explorer Limited 4WD, 98 AWD Mounty with 255/55/18's, big sway bars, and 12.75" x 1.25" rotors. Soon a BW4406, built trans, stereo and interior. The best thing that could help us all, is the Fair Tax Plan. Be American, Buy American (Manufacturer)

09-30-2007, 02:00 PM	#166
Turdle Old and in the way Humboldt, Kansas 2000 Mounty Join Date: Jun 2003 Posts: 23,787 Vehicle Specs (Original Poster)	Here is the orifice-just for understanding-- Attached Images __________________ Jon 2000 Mountaineer Turdle-gone Vitamin D Wagon Sold also

09-30-2007, 02:05 PM	#167
CDW6212R Elite Explorer Knoxville, TN 98 Mountaineer A4WD Join Date: Jun 2004 Posts: 13,016 Vehicle Specs	That will flow plenty of air. I see custom unit like that in my future, cut and welded together to fit. Thanks for the example. __________________ Don 91 Lincoln LSC/SE, 99/93 Explorer Limited 4WD, 98 AWD Mounty with 255/55/18's, big sway bars, and 12.75" x 1.25" rotors. Soon a BW4406, built trans, stereo and interior. The best thing that could help us all, is the Fair Tax Plan. Be American, Buy American (Manufacturer)

09-30-2007, 02:12 PM	#168
Jakee Elite Explorer Huntsville, Texas 01 Sport Join Date: May 2006 Posts: 2,808 Vehicle Specs	This EGR tube is the most expensive and has the most hours to make; EGR tube I've ever laid eyes on. __________________ STS turbo charged Last edited by Turdle; 09-30-2007 at 03:13 PM.

09-30-2007, 03:36 PM	#171
rocket 5979 Resident Gearhead Lake Villa, Illinois '03 XLT 4.6 Join Date: Apr 2002 Posts: 4,017 Vehicle Specs	Jon, I assume that you are going to make that throttle cable bracket yourself instead of sending your TB to me? Good luck with it. __________________ 2003 4.6 V8 XLT Black Explorer, Kenne Bell 2.2 Supercharger, VT Billet bottom end, MPH 2.5 Heads, Blower cams, A1000 custom fuel system, and on and on... 2009 6.6 V8 Pontiac G8 GT, Twin Turbo, 402ci, Turbocam, Circle D Built 6L80E, Circle D 3000 Stall, new fuel system on its way...Shooting for 750+rwhp and easy middle 10's. 2002 4.0 V6 Explorer Sport, CAI, Gibson Exhaust... 2005 3.9 V8 Lincoln LS, KBX Performance Garrett Turbo System...Sold...

10-01-2007, 03:27 PM	#173
Turdle Old and in the way Humboldt, Kansas 2000 Mounty Join Date: Jun 2003 Posts: 23,787 Vehicle Specs (Original Poster)	My Son Bryan is home for awhile-so we are doing some much needed fixes to his car-one of which was a new muffler. While there-I had the guy cut off the extra nozzle-and weld up the EGR tube. I'll be back to this-but for now I'm doing the "dad" thing for a day or 2. __________________ Jon 2000 Mountaineer Turdle-gone Vitamin D Wagon Sold also

10-02-2007, 10:19 AM	#175
410Fortune ELITE BRONCO2ERER Crawlorado B2 Mod Join Date: Aug 2000 Posts: 22,097 Vehicle Specs	$100 for an EGR tube? Holy moley!! running yet? __________________ 96 Explorer daily driver build-1996 XLT 5.0L AWD to 4x4 conversion complete on 33's 88 BII 5.0L conversion - BII 5.0l drivetrain thread My Bronco II - 1988 Bronco II 4x4 V8 on 35's - registry and updates Wifes 07 FJ build - 2007 FJ cruiser locked and lifted

10-02-2007, 11:53 AM	#176
Turdle Old and in the way Humboldt, Kansas 2000 Mounty Join Date: Jun 2003 Posts: 23,787 Vehicle Specs (Original Poster)	Not Fair!!! You have help--good help I'm on project Tempo-Bryan has my Grandmother's 91 Tempo with 40k on the clock--but it needs some attention. So far we have replaced the valve cover gasket and grommets-new muffler (Grandma had installed a lifetime muffler-but she's dead now and it fell off), new tires, oil change, radiator flush,fuel filter and spark plugs. Now we are cutting holes in the doors for his speakers. It will need some wooden spacers to clear the windows-so this will take the rest of the day. We are also installing a head unit I got from Dan, plus an amp and subwoofer. Nothing great-but he'll have some better than stock sound. He's looking for a nicer car-but this will be his daily beater. The brakes squeak-so we need to look them over. Then we are sanding the peeling window pillar trims and painting them black again, and a day is planned to go to the junk yard for some wheel center caps- The Mounty is on hold for a minute. __________________ Jon 2000 Mountaineer Turdle-gone Vitamin D Wagon Sold also Last edited by Turdle; 10-02-2007 at 12:08 PM.

10-02-2007, 01:01 PM	#179
chriswells78 Wannabe Elite Explorer Powell(Columbus), OH 96 XLT 5.0 4x4 Join Date: Nov 2005 Posts: 2,552 Vehicle Specs	I need a car like that to make into a mini-stock race car for my local track. LOL __________________ 1996 Ford Explorer 5.0 4x4... Too many engine mods to list in 6 lines 1999 Mustang GT 2002 Lincoln LSV8