Tips for removing EGR assembly on 2005 4.0.

[Nadrek]

Hello, new member here. Been lurking around for a week or so but can't seem to find the answer to my problem.

I'm getting a code P0401 "Exhaust Gas Recirculation flow insufficient detected." So I was planning on removing the EGR assembly to clean it out or possibly replace it.

I'm having trouble removing the exhaust tube from the EGR valve. It seems to be stuck/fused together pretty good and with the EGR being connected to the intake I don't think I should put to much pressure on it for fear of breaking the intake.

I tried heating it a little with a small butane torch but that doesnt get nearly hot enough and a normal torch doesnt seem possible without wrecking other items in the area (like the valve cover).

Anyone have any tips or ideas to break that sucker loose?

Thanks

 

[apenland01]

PB Blaster it and let it sit overnight. Then hit it again about 30 minutes before you try loosening it again. Use largest tool you can find or pipe to get more leverage. It's a pretty sturdy nut on that thing.

I'm in the same position with my 4.6L, that same code. Working on mine this weekend as well.

 

[Tech By Trade]

I ended up having to use a 2 foot cheater bar on the end of my wrench to break it loose. Dont tell the snap on guy when I bring the wrench in for warranty after it breaks....

 

[WaterBrat]

Egr 2005 4.6l

I had that code for a long time. Ordered a new EGR valve from rockauto. Once I placed the order I doused the nut on the tube and the 10mm mounting bolts with liquid wrench (I prefer PB Blaster but not readily available here in the Yucatan). Spraying it actually cleared the code. Since the part was on the way, I went ahead and planned to replace it. Sprayed 3 times several days apart, then again when I went to replace. I bought a new 1 1/16 combo wrench as there was not enough room to use my 14" crescent wrench. With the new wrench the bolt came loose although I had to get a hammer against the wrench to get it started.

 

[Nadrek]

Thanks for the reply everyone. Seems like a you all did pretty much the same thing. Spray it up with penetrating fluid and use some force to get it off.

I could do that but I am still concerned about damaging the intake. Looks like a couple of you did it on a V8. Not sure if the intake is plastic on the V8 like it is on the V6?

Thanks

 

[Number Twelve]

I was afraid of damaging the plastic intake so I removed the two bolts (8 mm IIRC). After the EGR valve is loose from the plastic, you can nuke it and not harm the manifold. I ended up taking the EGR to the bench vise to get it loose from the manifold bracket. Lucky the hot pipe wasn't too nasty to get loose. In and out in 110 minutes.

 

[Nadrek]

Got it out!

Ended up doing similar to what Number Twelve did. I was able to get out the two 10mm bolts holding the egr valve to the bracket. Then I started to work on the tube connected to the egr. The whole egr unit started to turn when trying to loosen the nut. Once it turned enough I put the biggest punch i had into one of the bolt holes and was able to break the nut free.

I ended up just replacing the egr assembly. Three days and no light. So far so good!

Thanks for the Help