Cant remove plenum - stuck on EGR tube? 99OHV

[ragajungle]

once everything is disconnected this should just lift straight up...right?
This EGR tube is not moving...I know from reading the "Lower intake removal" sticky that there is a washer in there, but am afraid to snap the plastic plenum yanking on it.

Wont budge.

Any suggestions - I am running out of day light.

 

[ranger7ltr]

The EGR tube is held in by a thick green washer...

If the plenum doesn't pull off, there are 2 bolts holding the tube to the EGR valve...Remove them...

But if you pull the plenum up and twist away from the lower intake, the connection will seperate...

The title should be...The EGR tube is held in by a thick green O-ring... There is no washer holding the EGR tube in place

 

[DB_1]

It's an O-ring inside holding the EGR tube to the plenum. I unbolted my dipstick to give me more wiggle room, it can be tricky so have patience.

 

[ragajungle]

Got it off - now onto the other problems

So here are the replacement gaskets (Felpro) what concerns me is the cardboard... the OEM are nothing like the replacement. They are individual - the replacement is a single piece...

does anyone have any feed back on the reliability of the cardboard replacement? It can't be any worse than the crap Ford uses

 

[ranger7ltr]

Reassemble after cleaning mating surfaces and torque properly...

The Felpro gaskets work exceptionally well... I have not had any issues with using this setup...In your box you did get the long single gasket that goes between the lower intake and the injector manifold, the 3 dual neoprene gaskets that go into the base of the upper plenum, and the thick green o-ring for the EGR tube in the upper plenum...

Is the original single long gasket thicker or thiner than the one you got inthe Felpro box?

 

[ragajungle]

The Felpro gaskets work exceptionally well... I have not had any issues with using this setup...In your box you did get the long single gasket that goes between the lower intake and the injector manifold, the 3 dual neoprene gaskets that go into the base of the upper plenum, and the thick green o-ring for the EGR tube in the upper plenum...

Is the original single long gasket thicker or thiner than the one you got inthe Felpro box?

ranger7ltr: Thanks for the quick reply.
No.... In the felpro gasket I recieved only 1 long single upper intake gasket kit (seen to the left of the OEM gaskets in above pics) and valve cover gaskets.. I recieved no green washer for EGR. Only upper 1 intake and 2 valve covers...

 

[ranger7ltr]

These are the gaskets I got for the upper plenum...

Here is a picture of them...And I also used the neoprene Perma Dry valve cover gaskets...

Now when i assembled my new engine this spring, the gasket set had the thin one piece lower center gasket and the 3 rubber[or plastic] double upper plenum gaskets...

I went to both Autozone and Advance Auto parts to find the upper plenum gasket set and I was not able to find them... You will need the green o-ring to seal the EGR tube to the upper plenum..

 

[Can EX]

We removed ours with the tube still in the plenum. There's a stub with a nut on it holding the egr and dipstick. Loosen that off and with the help of someone you should be able to pull the plenum up and wiggle the egr pipe through the vacuum hoses.