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5.0 whistling noise

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Does anybody know the correct part number for the male / male connector that connects the EGR tube to the exhaust manifold? I -think--the Ford number is F57Z-9F485-A (WRONG, see below). So far I'm coming up empty on a Dorman or other aftermarket option. Will call the dealer tomorrow to see if they have one on the shelf. Threads got wrecked on the tube end of the connector. Tried getting the one off my 3.0 manifold but it won't come out at all, with or without threads, no matter how much Mapp gas I give it.

Edit: Ford parts department says correct part number should be F1AZ. Will update if that fits.
Edit 2: Ford parts department was correct. F1AZ-9F485-A fit perfectly.
 



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I am pretty sure you can find similar at a good hardware store I remember making a spacer once.
For the intake spacer I just purchased a new EGR tube and bent it slightly to fit I mean the intake spacer is only 5/8"
There are like 3 different versions of the EGR tube, I like the newer Ford part with no accordion section the whole tube is smooth (2001 explorer v8 part)
Make sure you get all the long bolts you will need

I guess there is no chance of chasing those threads eh? LOL that sucker is FUBAR
 






Yeah, it's pretty well out of action for good at this point .

You posted that while I was on the phone with the local dealer. They can have a new one on Tuesday morning for $11, so that's good enough for me. I'll follow up on Wednesday or Thursday after the install is done (or I've failed and need help). Plenty of other projects to wrap up in the mean time to keep me busy.

I should have all the parts for the spacer. Complete kit with spacer and bolts, and I bought a replacement upper gasket for the one I've already used.
 






On close inspection, the threads for one of the EGR to intake bolt holes were screwed up. Because the bolt isn't easily visible from above, I'd assumed it was tight when the bolt suddenly tightened up. No idea what caused the threading issue, but once diagnosed it was a fairly easy repair by pulling the 90* adapter and chasing the threads. New tube, EGR valve, appropriate adapters and spacer (to match the intake spacer) have the engine running without any whistle at all.

Sounds a little wonky without any exhaust past the catalytic converters. I'll probably have that fixed on Monday after I sort out transfer case linkage and get the interior put back together a bit.

 






Hell yea yeeyeee
 






I swear I've hung around this thread too long considering I have an extra 5.0 in a Mountaineer and like the cammed sound too much.
 






Time to install a cam, eh?
 






Considering I've got two V8 trucks and an extra motor I won't comment, it's sure tempting considering the extra motor if I ever get it running is at 124K miles.
 






With a little luck, I'll find out in the next few days how it actually does pushing the truck around. Should be a healthy improvement over the worn out 3.0 it's replacing.
 






I know this is old but i just installed the phenolic spacer on my 96X with the 5.0 gt40 set up. Also did new injectors cleaned every last bit of everything, honed/smoothed out alot of casting gunk ect from the upper. Got it all back in one piece and now i have the exact and i mean exact same noise now. What did it end up being on yours? I will check the pcv like 410 mentioned but i installed a new one with new grommet and hose in this whole process even though i did not rtv it. Seemed like it pushed in pretty good to me with the new one. the old one was just kinda in there from the hoses being metal hard from age.
 






i have the exact and i mean exact same noise now. What did it end up being on yours?
>>> " On close inspection, the threads for one of the EGR to intake bolt holes were screwed up. Because the bolt isn't easily visible from above, I'd assumed it was tight when the bolt suddenly tightened up. No idea what caused the threading issue, but once diagnosed it was a fairly easy repair by pulling the 90* adapter and chasing the threads. New tube, EGR valve, appropriate adapters and spacer (to match the intake spacer) have the engine running without any whistle at all. "
 






Check the PCV valve :) Your 96 has internal EGR so you must have the intake gaskets all lined up perfectly, and good intake elbow gasket and a good EGR gasket at the EGR diaphram
Make sure no EGR leaks and again, check that PCV valve, they like to pop out of place and make a whistle
 






Check the PCV valve :) Your 96 has internal EGR so you must have the intake gaskets all lined up perfectly, and good intake elbow gasket and a good EGR gasket at the EGR diaphram
Make sure no EGR leaks and again, check that PCV valve, they like to pop out of place and make a whistle
[/QUOTE
Will do. I did not remove the egr or the iac i left them in place and just removed the TB and then the elbow with the egr in place and they didt leak before. I know that doesnt mean they arnt now but. I will check that pcv valve and make sure it really is in that hole, if i can get back there ill rtv it and see. I used new gasket on TB and Elbow but i did not rtv them and i ran out of copper coat doing the intake gaskets. i may take those back off and copper coat them after i get new gaskets for egr and iac After i check pcv and ill report back to you fine folks. Thank you all!
 






So! with everything being so tight i just started from the air filter back taking stuff off and checking everything. I got to the 90 or elbow and ghuess what!!! I am human and made a human mistake... I guess i didnt have my wrench on right or or had it up against some thing or flat did not tighten the very bottom back nut that goes on the stud that holds the fuel tank purge valve solinoid to the 90 witch is what tightens the 90 to the intake. Any way i caught that it was just hand tight barely and stopped there, checked the pvc it was good and put fresh gaskets from there back up and its silent again!!!! Thank you all!!!
 






YEAH!!!!!!!! well done
always check your work, one thing you learn mechanic-ing is when something goes wrong even when it seems unlikely, the NEW problem is usually the LAST thing you touched
 






So I just got finished tuning it up late last night, I re set my tps and idle/throttle stop and re set my air adjuster since after its first run down the hiway the butterfly wanted to stick a little. Hope it idles right and is done this am
 






Sounds like the PCV Vacuum line, sometimes they collapse and create a high pitched noise.
 






So as a final update Big Red is back out on the road and seems to be running as she should. All lights are off including from before the work and after now. Also according to the very in accurate torque pro app, my gps/ecu clocked 0-60 time has gone from 11.2 too 10.4 best out of three times. So it would seem all is in good standing and as it should be! Thank you all once again for the advice! I will put some pictures of my fancying it up in my profile tomorrow.
 






@kidrock72 pretty sure he solved the whistling noise :)

I want to see the pics!!
 



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i will have them up in a few minutes, working on it right now actually haha, it isnt actually cleaned up yet but you can see the idea.
 






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