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EGR tube repair

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Old 02-04-2007, 03:39 PM
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EGR tube repair

I tried this repair on my EGR heat tube and it worked like a champ.

It also saved me the $150.00 Ford wanted for the replacement part.

Like most it was broken off at the exhaust manifold.

I removed the upper flare fitting at the intake plenum, and measured the ID of the tubing. It was .550 ".
I found a piece of 1/2" (.500") O.D. copper tubing ( it would be considered 3/8" copper pipe ) and cut it to about a 2" length.

I then expanded the ID using a tapered drift so that it's O.D. measured .545".

I inserted the copper tube into the heat tube and then the whole assy back into the manifold. It should go right together and be an interference fit.

Re-install the top fitting into the plenum and you're good to go !
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