EGR Tubes Cause Hole In Intake Manifold

[RomeLaw]

First let me say I love my 1998 Explorer. It's really not an overstatement, so please dont think I'm being an idiot by asking this, but I'm compelled to.

I pulled off an EGR Sensor that looks like hot air just ripped to to shreds. Like an idiot I just let the hoses lay however in the engine, meaning to replace them shortly. I've come to now realize that they blow a hole in my intake manifold. Now after replacing the EGR Sensor and the MAF Sensor, I'm realizing this hole was the problem (previously I realized that the truck wouldnt stall out if I unplugged the MAF Sensor). Anyway, I'm wondering whether I need to replace the entire manifold or can I use something to plug that hole? A mechanic friend said that's the source of my problem and that air is getting in through that hole.

 

[Explorer2011]

Sure its not the tube itself?

 

[RomeLaw]

No it's not the tubing itself.

I've read in other forums where someone's used JB Weld to plug a hole in a Manifold. Stating that where the Manifold has not become brittle itself, thus prone to further breakdown, JB Weld can effectively plug a hole. Any thoughts?

 

[boominXplorer]

JB weld would work until it cracks and sucks into the motor and bends a valve. You can get an intake manifold cheap at a junkyard or I am selling one in this thread
SOHC for sale thread

 

[swetrid]

cat converters are plugged up and cause this concern.

 

[waskly]

cat converters are plugged up and cause this concern.

i second this.

 

[loblu04]

Hello I see this is a older thread but I am having this same issue on my 04 4.0. I have checked the back pressure and it seemed to be in a good range. I just put a new intake on and in just a few minutes there was a hole in the intake manifold again. Is there anything else the would cause this?
Thank you

 

[410Fortune]

Can you get a picture of the hole?
Somebody using too much starter fluid can explode an upper intake

In burnt fuel could also do this

The location and size of the hole has a lot to do with what maybe causing it

The new intake was it a used part?
I have heard this can be an issue with the 04+ sohc engines so I have been keeping the good intakes I get

 

[loblu04]

Well I figured it out. A bad egr valve and two cats that came apart and plugged up the last cat causing exhaust to go into the manifold and melt it. New y-pipe and jb weld patch on the intake and I'm back on the road. Thanks