EGR Tube Replacement - 1994 4.0L

[b05622]

My to-be mother-in-law has a 1994 Explorer that I helped them pick out. Recently the EGR tube rusted through at the base of the nut that secures it to the exhaust manifold. I was able to remove the old tube from the EGR, but I can't get the nut off of the manifold. I thought I was making progress on it, but I found out that I was actually turning the nipple it bolts to inside the manifold.

Does anybody have a tip for getting this nut off without damaging the manifold? I was concidering using my dremmel with a cutting wheel to slice the nut in half, hopefully not damaging the threads on the nipple. If it just won't come off, is this something I can cap off without affecting engine performance? The truck dosen't need an e-check where they live.

The mechanic won't touch it. He said usually taking that off involves ripping the nipple out of the manifold, thereby screwing up the manifold. Replacing the manifold then leads to broken off studs inside the head, and then pulling the head, tapping out the screws, and lost money for him.

I appreciate it.
Chris

 

[410Fortune]

first off the EGR is routed intot he upper intake, which is super easy to remove, you are not messing with the head bolts or anyof that stuff.


I am not sure how the EGR bung is fitted into the upper intake so I am not going to be much help there, but my best guess would be to remove the upper intake (takes like half hour) and work on this off the truck.
All you need is a new upper intake gasket and replacement EGR tube from the dealer

 

[b05622]

This is the lower pipe, where the EGR sucks off the exhaust manifold. I think the part you're talking about is the other side of the valve, between the valve and the intake. Are you refering to stripping the truck of the EGR completly?

 

[finnegan65]

I just had to do mine on my 94 explorer. I soaked the nut with PB Blaster for a day and then used a 1-1/16 combo wrench with a bar to break it free. If the threaded piece that the nut is on turns maybe you could get a vise grip on it. I'm not sure if that piece threads out of the exhaust manifold or not.

 

[410Fortune]

it should be welded as part of the exhaust
I am sorry I thought you were talking about the upper intake from your post. you need a bigger wrench, breaker bar, and smoe PB blaster, it will come off

 

[Mic_]

PB blaster with a little heat??? a torch.

If not run it for a few minutes at 2000 rpms then, shut it down then try to loosen it.