Hey all, I usually hang out over on the PSD side of the forum, but I am trying to help my neighbor with an issue on his '03 F-150. He has the 4.6 and the nut from the EGR tube has rusted off and now he has a leak, EGR codes, etc. I told him I would try to help him get it patched back up. I know I have read about the boiler compound and steel wool trick, but I think I would rather replace the nut and nipple that goes into the manifold. The issue is that he is being told that the EGR tube has been discontinued and he can't get one. I can source the nipple easy enough, but I'm not sure what to do about the nut. I'm curious if anyone has had any luck shortening the EGR tube, installing a new nut, then extending the nipple to allow it to be reinstalled. I was thinking that I read somewhere that the nipple just used a standard NPT, so I am thinking that regular hardware store parts should be able to be used to lengthen the nipple enough to have this work.

Another thought I had was that it might be possible to cut the flare off the end of the tube and use a compression fitting. Has anyone had luck with this?

I'm looking for suggestions.

Thanks!

 

In my experience if the nut rotted off then more than likely the nipple is rusted solid in the manifold, alot of heat with a torch is more than likely needed with the manifold off, and with luck it might come out. Thats after you battle rotted manifold studs and flange studs. I've seen people clean the nipple threads and install new pipe with muffler sealer in the threads, but that depends on whats left of the threads.
Hard to believe that the pipe was discontinued, strange.
I've seen people wrap exhaust tape around it with clamps just to get by until they fix it, usually replacing the whole manifold nipple and pipe, then using high temp anti-sieze on the install.
My .02

 

Ehh... That is no what I was hoping to hear...I have done manifolds before on these trucks (I had a '99 with a 5.4) and they can be a real pain. Anybody else want to weigh in?

 

It's Still available for $53. I'll bet the dealership still can get them to.
More Information for STANDARD MOTOR PRODUCTS ETB4

Also still available at Ford dealers: "Tube" http://www.silverstatefordparts.com/...SSION%20SYSTEM

 

That is the one listed for the 5.4 motor. Is it the same part for the 4.6? Rock Auto lists that one for the 5.4 but doesn't list one at all for the 4.6.... Is it the same part for all the mod motors?

 

I fixed mine by wrapping the whole area in aluminim tape....like the HVAC guys use on ductwork, then putting a clamp on each end.....it worked fine until I had time to R and R the manifold and tube....which was about 6 months duration. If you can get the nipple out of the manifold with some heat, and the threads are still good....I would think you could cut the original tube up higher, screw a piece of pipe into the manifold, then compression fit them together??? I finally tore the manifold and tube off and replaced everything....but as we all know it is a PITA....I busted studs...you name it....be prepared for the worst but maybe all will go smooth.

 

The Ford one I linked is for the 4.6L $40+, order it. 2nd one down on list.

It's listed as EGR line under the 5.4L. But not listed for the 4.6. Call Rock Auto and ask them, I've done it several times. See if it's the same part as the 4.6L? 1-866-ROCKAUTO (762-5288)

Or order this: http://www.silverstatefordparts.com/...SSION%20SYSTEM You can call them and make sure it's to.

 

I guess I am taking your word for it. It's odd to me that Rock Auto doesn't list one at all for the 4.6 but lists that one for the 5.4. Especially so if the engines both use the same part.

 

The Ford one I linked is for the 4.6L $40+, order it. 2nd one down on list.

It's listed as EGR line under the 5.4L. But not listed for the 4.6. Call Rock Auto and ask them, I've done it several times. See if it's the same part as the 4.6L? 1-866-ROCKAUTO (762-5288)

Or order this: http://www.silverstatefordparts.com/...SSION%20SYSTEM You can call them and make sure it is to.

 

Sometimes their data bases they buy has errors and omissions.
It take an act of God to ever get it updated.
Saw it at Advanced Auto and other places.
The local stores have no control over it unless they push which seldom ever happens.
The counter people can only go by what they see on their terminals unless they have personal knowledge.
The websites buy their data display programs and can have the same kinds of issues.
Good luck.

 

BTW, when I called the local Ford dealers parts dept. and asked about it last summer, they said the and confirmed that the new Ford EGR tube is stainless steel as is the original, nuts to. They would have to be, other wise they would have been gone ages ago due to rust.

 

Thanks for the help guys. I will let you know what happens. I told my neighbor that we could still get the tube, but I also told him that there was a possibility that the nipple and even the manifold may have to be changed to get everything done right. I think that was way more than he wanted to deal with so he scheduled an appointment to take it to an independent garage owned by some common friends of ours. I have done the manifolds on a couple of 5.4's before and I told him that it was doable but could take some time. This truck is his DD so I think he was willing to pay for the convenience of having it done quickly. I think he said he takes it in tomorrow. I'll let you know how it turns out.