I have to remove my upper intake to replace the EGR tube on my 5.0. Truck is a 96' 4wd, but the PO swapped the original engine for a 302 out of maybe a 94' or 95'(truly I don't know how to confirm the year of the engine, I'm just pretty confident it's not from a 96'). In any case I'm new to Ford trucks and have never done this. I understand broadly what has to be removed to get the upper intake off but I'm just looking for some tips/things to look out for. Anything else I should replace or check while I've got it off? Anything I should know in advance so I don't break something? Thanks in advance!

 

You can replace the EGR tube without removing the upper intake. Two bolts hold the EGR valve to the intake, and the EGR tube just threads onto the bottom of the EGR valve.
You'll probably have to soak both ends of the EGR tube in penetrating oil and let them set for a few days before you can get them to turn loose.

 

6 Bolts attach the upper intake on the lower, the center bolt on the drivers side is T40 torx IIRC and it's bit difficult to get at, you need a really long bit or a 6" long 1/4" drive socket and extension and it's a really good idea to tape all that together. You don't have to remove the TB from the intake and its easier to just unbolt the EGR valve from the intake than try and disconnect an old rusted tube from the it.

 

I would definitely prefer not to have to remove more than I need, I guess I just don't see how I could get to the lower part of that tube without removing the upper intake plenum first.

 

Is it necessary to drain the coolant entirely to do this? Also, besides replacing the gaskets, is there anything else I should give some attention to while I've got the upper intake off? Thanks for the info!

 

No need to drain the coolant at all. And I should have said the passenger side for that torx bolt, it's is accessed via a slot between the ports in the upper.

 

got it, thanks for the help!