Go Back   Ford Truck Enthusiasts Forums > Diesel > 6.0L Power Stroke Diesel
Sign in using an external account
Register Forgot Password?


6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van SPONSORED BY:

Reply
 
 
 
 
LinkBack Thread Tools Search this Thread
  #1  
Old 09-14-2008, 12:39 PM
Benchwrench's Avatar
Benchwrench Benchwrench is offline
Posting Guru
 
Join Date: Jan 2007
Posts: 1,302
Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.
EGR cooler up pipe removal instructions

I want to share the following procedure in hope that you will find this project easy enough to do yourself.
The exhaust up-pipe (or y-pipe) has to be removed in order to eliminate the "scoop" inside. This scoop highly restricts the exhaust gasses to the point that you may even see soot trying to escape where the exhaust manifold meets the head! This evidence of soot will show you just how restrictive this egr up pipe is, however the drivers side manifold does not have this scoop and does not exhibit soot at that union.

This is an easy one man procedure that most anyone can do with basic mechanics tools.

Enjoy!

The first step in this modification is to remove the downpipe from your turbo.
This is a great time to upgrade to 4" aftermarket pipes! In these pictures I've already in place a Stainless Steel Magnaflow exhaust system.

Using a zip tie at the transmission will hold the end of your wrench in place. This is looking up from the drivers side.

Click the image to open in full size.


The nylon tie will hold the socket firmly in place.
Click the image to open in full size.


Using an extension from the passenger side remove the nut. I used penetrating oil on each bolt thread.
Click the image to open in full size.


Take a magnet and remove the bolt. Notice the aftermarket 4" downpipe floating up in there.
Click the image to open in full size.


A good telescopic magnet is an invaluable tool for those hard to reach places.
Click the image to open in full size.


These two bolts are next. The upper bolt on the up-pipe and the stainless collar clamp on the egr cooler. They might look easy to get to but are way back in there near the firewall.
Click the image to open in full size.


Using the same trick at the begining, zip tie your wrench end while using a combination on the nut.
Click the image to open in full size.


A 3/8 air ratchet is the perfect tool for removing the egr clamp
Click the image to open in full size.


Slide the egr clamp over the cooler and away from the up pipe. At the different colored union you can see where the up pipe and egr cooler meet.
Click the image to open in full size.


Remove the lower bolts from the up pipe. Once all the bolts are removed, slide the now free pipe away from the exhaust pipe, This will give you room enough to fully remove the exhaust downpipe with ease. Now that the 4" exhaust downpipe is removed, you can easily remove the egr y-pipe.
Click the image to open in full size.


This pipe needed to be removed in order to modify it or replace it with one already modified. If you choose to replace it, Have one ready and on hand. You will need this for a refunded core charge.
Click the image to open in full size.


The sheer size of the Magnaflow 4" downpipe puts this factory exhaust y-pipe in perspective.
Click the image to open in full size.


The y-pipe is 2"
Click the image to open in full size.


Here's the "scoop" that needs to be removed
Click the image to open in full size.


The bright crescent area is the only flow area for the exhaust gasses, Now you get an idea why EGT's boils coolant so easily in the cooler, the exhaust is heavily Restricted. Just turning off the egr valve is not enough. This "scoop" has to go.
Click the image to open in full size.


In another thread I'll show how I modified this y-pipe.
This was just to show you how easy it is remove and replace the up pipe
__________________

"Because Stock is not an Option".
Reply With Quote
  #2  
Old 09-14-2008, 08:57 PM
moed moed is offline
Freshman User
 
Join Date: May 2004
Posts: 32
moed is starting off with a positive reputation.
thanks for the excellent write up!
Reply With Quote
  #3  
Old 09-14-2008, 09:31 PM
Joeymt3's Avatar
Joeymt3 Joeymt3 is offline
Senior User
 
Join Date: Oct 2007
Posts: 152
Joeymt3 is starting off with a positive reputation.
Thank you for this, a friend of mine is wanting to weld in a block off plate on the cooler inlet. this will be very helpful
__________________

'77 Bronco "under construction"
'99 Explorer 5.0 AWD
'08 Ranger 2wd 4cly & '97 Ranger 35 BFG's 2.3
2010 F-150 xlt 2wd & RIP '03 f-250 6.0
Reply With Quote
  #4  
Old 09-14-2008, 10:24 PM
Benchwrench's Avatar
Benchwrench Benchwrench is offline
Posting Guru
 
Join Date: Jan 2007
Posts: 1,302
Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.
apologies to all.
somehow some of the pictures loaded out of sync , wonder how I can fix 'em?
__________________

"Because Stock is not an Option".
Reply With Quote
  #5  
Old 09-15-2008, 12:19 AM
riggz's Avatar
riggz riggz is offline
Postmaster
 
Join Date: Mar 2007
Location: Dunwoody, GA
Posts: 2,612
riggz has a good reputation on FTE.riggz has a good reputation on FTE.riggz has a good reputation on FTE.
PM Maximum4x4 and ask him to edit it for you.
__________________
2004 F250 SD CC 4x4 Lariat 6.0 PSD
-R.I.P. 9/11/10
Reply With Quote
  #6  
Old 09-15-2008, 07:26 PM
GregsSD's Avatar
GregsSD GregsSD is offline
Posting Guru
 
Join Date: Dec 2006
Location: NorCal
Posts: 1,377
GregsSD has a good reputation on FTE.GregsSD has a good reputation on FTE.GregsSD has a good reputation on FTE.
Great writeup!!! I am getting ready to do this (already had the EGR cooler replaced once).

My idea to block off the scoop is to heat it up and bend it flush with the sidewall of the up-pipe
so that the scoop actually blocks off the outlet to the EGR cooler.

That way there will be no cutting or welding required and I can leave a very small opening so that
just a little exhaust can still pass through so that my CEL doesn't come on. I have a California truck!
__________________
2005 F-250 4X4 CC/SB 6.0 PSD, medium wedgewood blue
5" Procomp lift w/5"Donahoe rear springs, 35x13.50 Procomp Extreme A/T's on Ultra Predator 18x10 wheels, Street Scene fender flares,
Firestone Ride-Rite airbags, 4.30 gears, Harpoon mod, 2010 LED taillights, Color changing LED front turn signals,
SCT custom tuning, ARP headstuds, Banks turbo back 4" exhaust, Airraid intake
Reply With Quote
  #7  
Old 09-15-2008, 09:31 PM
satcom40's Avatar
satcom40 satcom40 is offline
Elder User
 
Join Date: Oct 2004
Location: Ct.
Posts: 577
satcom40 is starting off with a positive reputation.
Ok I have had a new up pipe for a couple year and now the warranty is up. and with this write up I'll have to give it a try. I think I'll get new hardware. does any one know what size the hardware is. and what about gaskets. Thanks all and Benchwrench
__________________
04 F-250 SD 6.0L XLT EC SB Black, May 04 build. Bypass filter for Oil & Coolant, Remote start, Pre-Post Luber, Scan Gauge, 46 gal fuel tank, Boost & Pyro.
Reply With Quote
  #8  
Old 09-15-2008, 09:31 PM
Joeymt3's Avatar
Joeymt3 Joeymt3 is offline
Senior User
 
Join Date: Oct 2007
Posts: 152
Joeymt3 is starting off with a positive reputation.
even if the pics are not in the right order, I still appreciate it. with your instructions we can still find the right pic for it.

we all have computer problems sometimes...Click the image to open in full size.
__________________

'77 Bronco "under construction"
'99 Explorer 5.0 AWD
'08 Ranger 2wd 4cly & '97 Ranger 35 BFG's 2.3
2010 F-150 xlt 2wd & RIP '03 f-250 6.0
Reply With Quote
  #9  
Old 09-16-2008, 01:38 PM
Benchwrench's Avatar
Benchwrench Benchwrench is offline
Posting Guru
 
Join Date: Jan 2007
Posts: 1,302
Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.
Quote:
Originally Posted by GregsSD View Post
Great writeup!!! I am getting ready to do this (already had the EGR cooler replaced once).

My idea to block off the scoop is to heat it up and bend it flush with the sidewall of the up-pipe
so that the scoop actually blocks off the outlet to the EGR cooler.

That way there will be no cutting or welding required and I can leave a very small opening so that
just a little exhaust can still pass through so that my CEL doesn't come on. I have a California truck!
I was originally thinking about this too however came to this conclusion;

The scoop is part of the pipe and has been already stretched out of shape. Any attempt at massaging it back into place will never get it smooth enough even if plasma cut down the center then welded together. Anyway, once the scoop was formed back into place the y flange to the cooler would end up canted and would never again sit flush to mate to the egr cooler inlet and will still transfer exhaust heat to the cooler.
IMHO, too much work to make it look OEM.
BUT if you want to try it that way, please post the outcome.
__________________

"Because Stock is not an Option".
Reply With Quote
  #10  
Old 09-16-2008, 07:39 PM
GregsSD's Avatar
GregsSD GregsSD is offline
Posting Guru
 
Join Date: Dec 2006
Location: NorCal
Posts: 1,377
GregsSD has a good reputation on FTE.GregsSD has a good reputation on FTE.GregsSD has a good reputation on FTE.
The scoop can also be carefully cut out with a sawsall, then the egr tube can be blocked off.

Here's some photos I found from someone who did it this way:

Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
__________________
2005 F-250 4X4 CC/SB 6.0 PSD, medium wedgewood blue
5" Procomp lift w/5"Donahoe rear springs, 35x13.50 Procomp Extreme A/T's on Ultra Predator 18x10 wheels, Street Scene fender flares,
Firestone Ride-Rite airbags, 4.30 gears, Harpoon mod, 2010 LED taillights, Color changing LED front turn signals,
SCT custom tuning, ARP headstuds, Banks turbo back 4" exhaust, Airraid intake
Reply With Quote
  #11  
Old 09-17-2008, 09:46 AM
Kep4's Avatar
Kep4 Kep4 is offline
Jäger
 
Join Date: Jan 2005
Location: LA/OC, Kalifornia
Posts: 5,482
Kep4 has a spectacular reputation.Kep4 has a spectacular reputation.Kep4 has a spectacular reputation.Kep4 has a spectacular reputation.Kep4 has a spectacular reputation.Kep4 has a spectacular reputation.Kep4 has a spectacular reputation.Kep4 has a spectacular reputation.Kep4 has a spectacular reputation.Kep4 has a spectacular reputation.Kep4 has a spectacular reputation.
Thanks for the write up and the great pics!

Rep 2U!
__________________
Russ
'12 F350 Lariat CCLB 4x4 6.7
'13 Fuzion 315 5th wheel
'05 F250 Lariat CCSB 4X4 6.0 - Sold

Rest In Peace, Steve P. You are missed.
Reply With Quote
  #12  
Old 09-17-2008, 01:36 PM
glm racers glm racers is offline
Senior User
 
Join Date: Jan 2007
Posts: 306
glm racers is starting off with a positive reputation.
Thank you.
This is exactly what I've been trying to find
Would you have the procedure to bypass the EGR cooler i.e. use the stock up-pipe, that has been blocked, and re-route the coolant lines from the oil cooler back to the water pump??
I'd like to keep my cost down by blocking the stock up-pipe and using the cooler to support the flex joint.
Also, by eliminating the exhaust flow to the egr valve would the valve send a CEL code??
I have an 03 build date 1/1/03
Thanks,
Gilbert
Reply With Quote
  #13  
Old 09-17-2008, 01:53 PM
GregsSD's Avatar
GregsSD GregsSD is offline
Posting Guru
 
Join Date: Dec 2006
Location: NorCal
Posts: 1,377
GregsSD has a good reputation on FTE.GregsSD has a good reputation on FTE.GregsSD has a good reputation on FTE.
Quote:
Originally Posted by glm racers View Post

Also, by eliminating the exhaust flow to the egr valve would the valve send a CEL code??
I have an 03 build date 1/1/03
Thanks,
Gilbert

I don't think you will get a code on your 03, but the newer trucks and definitely the California trucks will give you the CEL. That is why I do not want to block mine off completely.
__________________
2005 F-250 4X4 CC/SB 6.0 PSD, medium wedgewood blue
5" Procomp lift w/5"Donahoe rear springs, 35x13.50 Procomp Extreme A/T's on Ultra Predator 18x10 wheels, Street Scene fender flares,
Firestone Ride-Rite airbags, 4.30 gears, Harpoon mod, 2010 LED taillights, Color changing LED front turn signals,
SCT custom tuning, ARP headstuds, Banks turbo back 4" exhaust, Airraid intake
Reply With Quote
  #14  
Old 09-17-2008, 04:20 PM
glm racers glm racers is offline
Senior User
 
Join Date: Jan 2007
Posts: 306
glm racers is starting off with a positive reputation.
Quote:
Originally Posted by GregsSD View Post
I don't think you will get a code on your 03, but the newer trucks and definitely the California trucks will give you the CEL. That is why I do not want to block mine off completely.
Forgot to mention that mine is a California six-oh with 74k miles, and it's out of warranty.
Last month I cleared a P0401 code and I've never removed the EGR valve and I've kept the engine/drivetrain/tires stock without any tuners.

In studing the 6.0 bible it appears that the flow of the exhaust gas is implied by the voltage sent back from the EGR valve???

I'd like to prevent the common egr cooler leak, so any advise would be appreciate.
Reply With Quote
  #15  
Old 09-18-2008, 06:27 PM
Benchwrench's Avatar
Benchwrench Benchwrench is offline
Posting Guru
 
Join Date: Jan 2007
Posts: 1,302
Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.Benchwrench has a great reputation on FTE.
Quote:
Originally Posted by GregsSD View Post
Great writeup!!! I am getting ready to do this (already had the EGR cooler replaced once).

My idea to block off the scoop is to heat it up and bend it flush with the sidewall of the up-pipe
so that the scoop actually blocks off the outlet to the EGR cooler.

That way there will be no cutting or welding required and I can leave a very small opening so that
just a little exhaust can still pass through so that my CEL doesn't come on. I have a California truck!
I think you have a better idea with the pictures you listed by using a sawsall. If I thought I could have done a good job with a sawsall, that is the way I am sure that I would have chosen first because of what you state (more stability with the Y for support). Also by using a dremmel tool, I'm sure you could clean up any burs and fraged edges to keep 'em from being sucked up into the turbo .
Will just have to give this thing some time and find out just how durable this patch job is going to last.
__________________

"Because Stock is not an Option".
Reply With Quote
Old 09-18-2008, 06:27 PM
 
 
 
Reply

Similar Threads
Thread Thread Starter Forum Replies Last Post
Rebuilding the 6.0 VGTurbo Benchwrench 6.0L Power Stroke Diesel 54 01-30-2014 01:47 PM
Turbo Housing Leak. Now what? cg_wilson2003 6.0L Power Stroke Diesel 9 04-07-2013 10:07 PM
Heated seat indicators Benchwrench 6.0L Power Stroke Diesel 27 02-20-2013 11:02 PM
Seat Swap mudder460 1973 - 1979 F-100 & Larger F-Series Trucks 5 11-17-2009 05:28 PM


Go Back   Ford Truck Enthusiasts Forums > Diesel > 6.0L Power Stroke Diesel

Tags
2006, 60, cooler, cost, diesel, egr, f250, ford, forums, insructions, powerstroke, ranger, removal, replace, truck, valve

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On

Forum Jump


Participate In The Forums

Create new posts and participate in discussions. It's free!

Sign Up »





All times are GMT -5. The time now is 12:40 AM.


Powered by vBulletin® Version 3.8.7 AC1
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Advertising - Terms of Use - Privacy Statement - Jobs
This forum is owned and operated by Internet Brands, Inc., a Delaware corporation. It is not authorized or endorsed by the Ford Motor Company and is not affiliated with the Ford Motor Company or its related companies in any way. Ford® is a registered trademark of the Ford Motor Company.

vbulletin Admin Backup