Do I have to drill and tap the exhaust manifold for the EGT gauge sensor on a 2001 Ford F-250 7.3 4X4 truck?

 

Yes, they don't have an tapped opening from the factory. Since you're installing pre-turbo you may want to consider drilling and tapping just afert the Y but before the turbo - that way you'll have the reading from both sides of the engine instead of just one. Also, you're going to need to take it off to drill and tap so you can clean all of the metal shavings out, otherwise you'll wreck your turbo.

 

GCourvill,

Two ways to install.
1.) Drill and insert the probe and use the clamp method.
(usually included in the EGT gauge kit)
2.) Drill and tap with NPT 1/4" or 3/8" depending upon the size of the threaded collar.

No, you do not have to remove to drill or tap the manifold.
Use grease on your bit and tap when drilling and tapping.
Use a small magnet to insert into the hole after drilling and tapping to collect any shavings.

If you are not comfortable tapping the manifold then I suggest you go with the clamp installation.

 

Taking it off is cheap insurance vs. a new turbo - unless you're planning on upgrading anyway. Besides, I always like to make sure I get things in straight.

 

I've done a few of the drill and tap installs and and have found little to no shavings. (You must be very patient when drilling and tapping).

What little remnants I did have were so miniscule that they would have passed through the turbo without any problem or damage anyway.

I've even read where a few have installed them while the engine is running.

Whatever make you feel good.

 

I guess I'm just a bit too conservative. I know people who have installed the sensor as you describe with no problems, but that's never really been the type of luck I've had. Can't say as I've ever heard of anyone installing anything while the truck is running.

 

As stated above you have to drill no matter which way you go. I have the clamp-on thermocouple, you can see it in my pics. I wouldn't worry about shavings. After drilling, star the engine and idle it for a minute. Any shavings will pass the turbo without harm.