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egr tube is broken

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Old 10-27-2012, 05:10 PM
ltyler179 ltyler179 is offline
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egr tube is broken

Hey all, thanks for all the forum help... first time asking about a problem IO couldn't find on a search.

My 96 F150 5.8 has been coding 1405 and 0401 off and on for a while now. read the posts and leak searched, tested the EGR valve and the DPFE sensor. Both OK.

Worked on it some more today and found the culprit... one of the sensor tubes coming off of the large EGR riser is broken off at the weld.

So my question... any tips/tricks to removing the EGR tube from the exhaust manifold???

Thanks for any help on this one.
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Old 10-27-2012, 07:30 PM
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rla2005 rla2005 is offline
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Originally Posted by ltyler179 View Post
Hey all, thanks for all the forum help... first time asking about a problem IO couldn't find on a search.

My 96 F150 5.8 has been coding 1405 and 0401 off and on for a while now. read the posts and leak searched, tested the EGR valve and the DPFE sensor. Both OK.

Worked on it some more today and found the culprit... one of the sensor tubes coming off of the large EGR riser is broken off at the weld.

So my question... any tips/tricks to removing the EGR tube from the exhaust manifold???

Thanks for any help on this one.
Heat cycle it several times then spray the connections with PB Blaster in between cool down cycles.

BTW...where did you get your replacement EGR tube? They can be tough to find.
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Old 10-27-2012, 08:31 PM
ltyler179 ltyler179 is offline
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Hey rla, thanks for responding.

Ended up taking out the inner fender to get at it, heated and PB blasted already... got the nipple loosened from the manifold but can't break the flare or compression nut. Really tough spot to try to fit opposing wrenches.

Actually haven't found a replacement yet so thanks for heads up on finding one before I whack it with the sawzall.

Thanks again... I'll keep you posted.
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Old 10-28-2012, 03:24 AM
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minnesotafisherman minnesotafisherman is offline
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Only place you'll find a replacement is the junkyard.
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Old 10-28-2012, 10:30 AM
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Originally Posted by minnesotafisherman View Post
Only place you'll find a replacement is the junkyard.
Sorry to disagree with you..

Amazon.com: Ford F5TZ-9D477-E - TUBE - EGR VALVE TO: Automotive Amazon.com: Ford F5TZ-9D477-E - TUBE - EGR VALVE TO: Automotive

F5TZ-9D477-E - Ford TUBE - EGR VALVE TO

OE Ford F5TZ9D477E Tube EGR Valve To | eBay

Just to name a few

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Old 10-28-2012, 03:26 PM
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I got mine from a local dealer. Expensive, but the only place I could find it at the time.
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Old 10-28-2012, 03:51 PM
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The 1996 F150/Bronco models were among the first to start using the DPFE style EGR system. That makes these tubes very expensive and hard to find from time to time. PCI Inc. has pleny for the earlier style trucks/cars that use an EVP, position feedback, EGR system but they do not carry the DPFE style on this vintage truck.

The photos listed with the EGR tube I listed may not be of the actual part. Ford revised it to eliminate the crack prone "accordion" section. I hope this nets what the OP is looking for.
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Old 10-28-2012, 04:08 PM
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Ive got the same leak on that tube. mine has the exhaust leak sound upon taking off! I'm glad that I still can get new part for now.
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Old 10-29-2012, 03:21 AM
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It's all good...

At least if you want one cheaper the junkyard is not a bad option...
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Old 10-29-2012, 06:07 AM
ltyler179 ltyler179 is offline
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Thanks rla2005 for the correct Ford part # F5TZ9D477E

All I could find even using my VIN was F0TZ9D477A which was the wrong part. At the Ford sight, I only found the 9D477.

How did you find the right part #? Really appreciate the help.
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Old 10-29-2012, 03:04 PM
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Post# 9 in this thread: 96 5.8L EGR Tube Removal - FSB Forums A quote from my buddy miesk5 in his reply had the part number.
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