Help, broke EGR casting!

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Jun 5, 2012 | 04:18 PM

SwiftDB4

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Help, broke EGR casting!

In trying to disassemble everything to get my fuel injectors out for cleaning I broke the EGR valve casting at the junction with the pipe going down to the exhaust manifold. In hindsight I should have just unbolted the EGR at the intake manifold, but too late now. The broken casting needs to be removed from the upper pipe fitting. My problem now is trying to remove the pipe at the lower end where it screws into the exhaust manifold. Tried penetrating oil and heat (MAPP gas) with no luck so far. Are any of the freeze products any good? Any other suggestions? I'm really paranoid now about breaking the lower fitting and compounding the problem. Thanks.

Jun 5, 2012 | 08:25 PM

kid1994

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Do you have a picture? Anyway I would try cutting relef cuts in the part your removing. just be careful not to cut into anything you need. sorry thats my only idea, hope it helps.
good luck

Jun 5, 2012 | 10:15 PM

Blue Rebel

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From: Cottage Grove, WI

a new pipe isnt that much from oreillys...

Jun 5, 2012 | 11:45 PM

SwiftDB4

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I'm expecting to have to replace the pipe. I just can't get the lower fitting loose at the exhaust manifold. Don't want to break that one too.

Jun 6, 2012 | 12:25 AM

fordbozo

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Joined: May 2009

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From: Manzanita, OR

There's a youtube vid where the guy blazes that lower nut to red hot before he can get it loose...

I'd recommend hourly doses of pb blaster and daily tweaks with a wrench to see if it moves. 5:00 into this video:

http://www.youtube.com/watch?v=50GJ_BSmgAo

//mods, sorry if posting live links isn't acceptable, I'm not sure what the rules are regrading posting links, if this is incorrect please let me know and I'll not do it again...

Jun 6, 2012 | 12:27 AM

Blue Rebel

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From: Cottage Grove, WI

^^^ Best tool i ever bought for home use was a MAPP gas torch. hotter than propane, and still under 50 bucks. heat is a must when working with stuff like this.

Jun 6, 2012 | 01:33 AM

fordbozo

Mountain Pass

Joined: May 2009

Posts: 210

Likes: 6

From: Manzanita, OR

MAPP gas torch? I was wondering what that thing was, cuz it certainly doesn't look like oxy-acetylene. Off to google that now... LOL!

...edit...
well, that thing is oxy-acetylene. Still googling...
...edit...