I was looking at an 08 w/ 4.6L V8 locally and it has an EGR code. Its no wonder......the egr is rotted out to the point the metal body and plastic top have seperated. The tube going from the drivers exhuast manifold looks good & appears to be stainless steel, but the big nut that connects the tube to the EGR is disintegrated. There is no way to get the egr off without cutting the stainless tube. The other end that goes onto the ex manifold is also rusted and nasty. The shop said they would need to replace the entire manifold, tube, and egr for around $1500.

1.) is there a way to cut the tube and use some kind of coupler, again the tube somehow is still good even though the ends are not.

why are these parts rotting out. I have noticed my F150's and crown vics also have crappy rusty EGR's but thankfully no codes.

I will add that the rest of the truck in question is not really rusty, so not sure why this EGR got so bad........

 

If it's the tube I'm thinking of (P/N 7L3Z-9D477-A), it's still available from Ford for a list of around $54.00. The EGR valve (P/N 7L3Z-9D475-B) is around $206.00.
You can find the parts cheaper online.
EGR SYSTEM for 2008 Ford F-150

 

The guy has the parts to offer with the truck, the issue is there is no way to get the tube off the egr, or the more important part, to get it off the manifold. What can he or I couple the pipe with. I would be interested in this truck if it could be fixed cheap.

 

Probably will also be dealing with broken exhaust manifold studs when changing out the exhaust manifold which could add even more $ to the cost....