The OEM pipe had a flexible piece as you can see. The new one I ordered is a Dorman and does not have the flex part. In addition to having to use a torch to remove the old one from the exhaust manifold, making the new one fit without the flex was unreal. The new one is actually a little shorter than the OEM. The two ends located at the exhaust and the EGR are IMPOSSIBLE without bending the pipe by hand. Figuring out how and where to bend it to fit both ends was a major project. But it is finally installed and it is absolutely a two person job. If you ever have to replace one on a 460, I have some tips but plan on it taking some time. Hope you never have to do it. Sandy


Broken piece at exhaust from trying to remove nut from top of pointed piece. Now get the piece of pipe out of the exhaust.

Old EGR with piece that flexes just a little

Start by removing this nut. Good luck

Left is the replacement for the broken one. Available everywhere..

 

Being former Air Force, I was taught by the base hydraulic shop, the best penetrant is a 50/50 mix of acetone and ATF. That concoction will break loose shi . . . stuff, I meant stuff, that's beyond PB Blaster's ability to break loose. Back then we used Dexron II but I guess any of the Dex/Merc fluids could be used. I still have a can of Dexron II & acetone that I mixed in the '80's to tear down a '56 Ford Victoria Club Coupe. Was supposed to be an Arizona car, found out through title search it was a SLC, Utah car beforehand. Very rusty underneath but we got it apart with that concoction in a Plews hand type trigger pump can to administer the liquid.

Glad you brought up that issue with the replacement tube being not to spec, I will need to do that eventually when I do the Banks Headers on my 460.

 

I was looking at the Banks Headers the other night. The Stinger kit. Those two pieces in my pics came with block off plates for a nice EGR delete which you probably will do if you go with the Banks. I had a Stinger kit on an old 7.3 back when, and it was nice quality stuff. Sorry about all the boot marks we made down the side of your planes. Sandy

 

ROFLMAO! What little bit of coffee I didnt spray, was because the rest went down wrong pipe, I bet thats a camp fire story!

 

Nope, will be leaving the EGR system working. I like to run timing a little high (13-14°) and I don't like to hear preignition cruising down the roadway. My truck needs the EGR intact to cool the chambers while cruising. that reminds me; need to source more of that plastic hose to repair more brittle vacuum hoses.

And, now I know who was putting boot marks on my F4-D Phantom II fighters! I thought it was the armament grunts trying to load bombs and missiles the hard way.

 

Just installed a set of Banks headers on my 97HD 460. I used the Banks headers that don't have the air injection ports.
Original EGR tube was so rusted that I had to cut it off. I contemplated just deleting the EGR system, but decided that it would be cheaper and healthier to leave it working, so I had the local parts store order the Dorman EGR pipe. When I installed the EGR pipe I hung the header by getting a couple bolts just barely started, applied some anti-seize to the header side of the EGR pipe and started it hand tight. I did this from the top. It was a little awkward reaching in there with my right hand, but do able. I then applied anti-seize to the EGR and attached it loosely to the pipe.
Maybe I got lucky at this point, but I had just enough wiggle in it all that I was able to get the EGR mounting bolts started. It didn't look like it was going to line up, and was worried I would have to fenagle the pipe like you talked about sandymane, but I decided I would just go easy on the bolts and try to evenly tighten them. Next thing I knew they were in tight, and sure enough the EGR had completely seated. I proceeded to finish installing the header and in the end everything sat tight with no leaks!

I'm thrilled with the new headers by the way. I was hesitant to drop that amount of money on them, but overall I would say they were definitely worth it. Even though it took me a good while to get them finished (started right before Thanksgiving holiday) I consider myself extremely lucky in the whole installation process. The old manifolds gave almost no fight in coming out, every one of the old bolts was no more than hand tight. The hardest part in in removing everything was using a Sawzall

 

What a great story. CONGRATULATIONS. Really glad it worked out like that for you. All those different pieces rarely go that well. You're living right. Sandy

 

Just did the banks system. Headers and exhaust. Love it! But, don't delete the egr. I did delete the air pump, so I made a plate to block off the passenger side air pipe on the new headers. Drivers side has 2 bungs. 1 for air pipe, 1 for egr. Put a pipe plug in air pipe bung with high temp sealant. Dorman makes an egr tube for my 460. I found if I loosely attach it to my headers, and egr, and egr is attached to upper intake. I can then manhandle my upper intake into place, tighten up the 4 bolts, then go back and tighten the egr tube. Have done this twice now since installing Banks kit with no issues.

 

I just replaced my EGR tube. Same thing, it was a Dorman. It would not line up, so I cut the tube just below the flexible area. I installed 3" of 3/4" high temp silicone hose. This made life way easier. I have a 1996 F250 4x4 7.5 crewcab short box. I bought it new in March of 1996. My everyday driver. Still looks new!

 

what are those pieces called?