Picked up my 2001 5.4 from the salvage yard last night and today, while pulling the exhaust manifolds, discovered the salvage engine has an egr tube from the driver manifold but the one in my truck does not. I plan to take EVERYTHING off of my engine and swap it to the new but I was just wondering if the lower end and heads are the same as what I have now? Any other surprises I might encounter and what did the 5.4 with the egr come in? Supposedly this was an F150.

 

I would imagine just about every gas vehicle made after about....say 1976? came with an EGR so I would speculate that yours was removed by a previous owner unless it came from some type of pump or marine application where emission controls were not required. Good luck with your project!

 

While this maybe true for most cars and trucks it's not for the super duty at least the 99-04 version in question the only year that had egr was 99 on either gas engine California emissions or not due to the weight of the truck it's not required by .gov that's why the since the motor came out of an f-150 it has an egr it was required just use your manifolds.

 

Thanks Mike and sorry for the misinformation Hoping to see a happy ending for GN1220 throughout this ordeal you have been a trooper thus far.

 

Apparently the location of the oil filter is different, as is the oil pan, pick-up tube, and intake. And those are just the visual differences we noted. Not to mention the engine has 194,000 miles instead of 118,000 as I was told. Engine is going back and I'm pulling the heads on my engine. Maybe then, just maybe, I can drive my truck.

 

Damn. You are literally catching no breaks on this thing yet.

 

My friend suggested selling it moving on. He may be correct. Tearing engines apart and working on a daily driver in a hot/cold shop aren't as fun and cool at 44 as they were at 24. I bought this thing to help grow my side business and get out of my (very cool) wagon with 300,000 miles on it. Now the wagon is having new issues, my side jobs have been put on hold and the truck needs more attention and $$$$. I'm guessing another 3 weeks, at least, before we can get the heads done. Next weekend it's off to Chicago to visit family so those three days of the holiday weekend are out. I'm a great big dummy.....

 

It will get better I swapped 99 expedition with the 01F250 super duty had the exact same problem all they do is block off the EGR in ram I've manifolds and ran fine

 

Just replaced the driver side exhaust manifold and EGR tube. Unfortunately I still have a ticking noise, not sure if it's due to a loose new egr tube or the new manifold gasket being off, all 8 studs of the manifold were torqued to 20 ft-lbs. I found the EGR tube (dorman 598-115) from AutoZone, but noticed it wasn't bent quite perfectly to mate the flared connections on the valve side, I was able to thread the flare nuts on both sides of the tube, but would the flared ends not being perfectly flush under the nut cause the noise, even though the nuts are screwed on?

New manifold bolted up on driver side, used 2-piece gasket that came with the manifold

EGR tube connection to the new manifold

New flare connection from EGR tube to egr valve

I used a sawzall to cut the EGR tube above the exhaust manifold, the nut was so rusted to the pipe thread, there was no possible way of getting the old tube off without damage. Also the old exhaust manifold gasket seemed destroyed, yet the sound is just as bad with the new manifold/gasket and EGR tube installed.

 

That misalignment at the valve looks substantial. The tube needs to be adjusted to get a straight shot at the fitting.

 

I thought that valve /tube connection was messed up... To be honest I was just way too tired after replacing everything to take it out in the dark and try to bend the tube. Right now it's bent from the factory so that it's gonna be at an angle either a the manifold side or the valve side (as seen), gonna need to do some work in the vice and tube benders.... Gonna take it out when I get a chance and try to bend the tube so it fits better, and I'll post the results! Hopefully that solves the ticking noise.