I really have read all the posts on the EGR issues related to the welding/plug on the up-pipe that connects to the EGR cooler/system.
I want to do this mod, I am looking for the steps to get this pipe out.
I can get to the manifold connection under the truck. How do I get to the Y connection and the cooler connection? Remove the exhaust pipe from the turbo I am guessing.
I am going to do the CCV mods at the same time, so the air intake system will be removed. Will I be able to get to the upper joint behind the turbo. I dont want to remove the turbo
Also doing the cat muffler -straight pipe mod. Using stock 3.5 pipe for now.
BIG mod weekend with my car tech son.
Thanks for the help

 

I believe Diesel Power mag. has done an article on EGR Delete Kit, its been a couple months. they had fairly indepth instructions. maybe someone will chime in and tell you what issue it was

 

for the time being check the "tech folder" and look for the EGR DELETE
its a sticky at the top of the 6.0 forum page
good luck

 

Thanks - I did the above -over 2 hrs of reading over 3 days WOW good info -- but no real step by step direction how to get the pipe out to weld it. The Ford shop DVD talks about the Y pipe replacement and that requires the turbo removal. Don't want to go there. So if we can't figure it out , we wont do it. Thanks

 

Remove the right front inner fender and down pipe you can then get at all the bolts and the clamp at the egr cooler. Its a pain but can be done. I took me a couple of hours just using a floor jack.

 

Remove the right front tire.

Remove the right front fender liner.

Loosen the downpipe to turbo clamp

Loosen the downpipe to cat flange bolts.

Remove the uppipe to right side exhaust manifold bolts (2)

Remove the uppipe to y-pipe bolts (2)

Loosen the uppipe to egr cooler clamp.

Remove the uppipe. Wiggle the downpipe around as necessary.

I probably forgot something, but this should be close. After you weld the egr hole in the uppipe shut and reinstall, also reinstall the clamp that holds the uppipe to the egr cooler. Some people say not doing so will cause the uppipe to crack at the flexible section. I didn't want to find out the hard way they were right.

 

Job done - will write up all the mods we did this weekend later, thanks to all for the help

 

good job!!!

did the up-pipe fall on your face? they have a tendancy to do that..