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96' EGR pipe trouble

cede

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Joined
August 5, 2007
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Year, Model & Trim Level
96 4WD
Hello all,

On my 96 XL explorer, 4.0 V6, I'm on my way of changing the upper engine gaskets because right head gasket is pretty dead and left was about to split too.

I had lots of trouble removing some bolts from the exhaust manifold.
I had to use a grinder to get rid of them as some bolts' heads got rounded.

During the left head removal, I heard a strange noise... ok that was the EGR pipe bending. When I took a look at it, it was rotten as hell and showed a little crack that became a large one and the pipe felt down.

The big deal of the day is... should I change the EGR valve and the pipe even if the thread on the exhaust manifold is screwed. The valve is rotten and the pipe is soldered on it by rust ?

I was thinking about blocking the port on the exhaust manifold and get rid of the EGR system, but I'm not sure about how to do that.
Is there anything special to take care about ?
What will it do if I plug back the valve, dpfe and so on with a sheet of metal to block the egr intake at admission ?

Thanks a lot, I'm really new to those engines
 






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