EGR cooler clamp problem - Ford Powerstroke Diesel Forum
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post #1 of 6 Old 09-03-2011, 01:34 PM Thread Starter
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EGR cooler clamp problem

So I replaced my EGR cooler and oil cooler. All was good. Truck started right up but had a hiss. Turns out I have an exhaust leak where the EGR cooler hooks into the exhaust. I tried tightening the clamp some more and ruined the clamp. I pulled it out and purchased a new one. I can get the clamp on but not spun around the end is to big to pass under the cooler. The old one came out so I figure the new one must go back on. Any suggestions?
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post #2 of 6 Old 09-03-2011, 02:21 PM
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there's a thin metal gasket that goes on the end of the cooler, it'll fall out pretty easily and dissappear without a trace if you don't know it's there

the clamp should go on, it's a little tricky, try installing it around the up-pipe first and spreading it over the flange

-Matt

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post #3 of 6 Old 09-03-2011, 02:58 PM Thread Starter
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Quote:
Originally Posted by sinner6.0L View Post
there's a thin metal gasket that goes on the end of the cooler, it'll fall out pretty easily and dissappear without a trace if you don't know it's there

the clamp should go on, it's a little tricky, try installing it around the up-pipe first and spreading it over the flange
I am aware of the gasket, but this clamp once off will not go back on. When I say off I mean completely off the pipe and in my hands. Now when I put it on the pipe it will not spin because the ends are to big to go under cooler. I have been at this all day trying to get it on. I have the passenger side down pipe undone, the turbo up pipe undone and and the driver side turbo up pipe undone and i still can not get it back on. I can not believe I have to pull the intake to put this back on. The old one came off so it only make sense the new one would go back on.
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post #4 of 6 Old 09-03-2011, 03:24 PM
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it will go on, keep messing with it

-Matt

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post #5 of 6 Old 09-03-2011, 04:56 PM
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There is a bolt head right under the clamp that will cause you a lot of frustration. Open it up and get it around the up pipe behind the flange with the opening pointing down. then slip it over the flange and rotate it around the correct direction with the opening on top and tighten down. I didn't remove my manifold and mine just fell right on.
GOOD LUCK.
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post #6 of 6 Old 09-03-2011, 05:08 PM Thread Starter
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Quote:
Originally Posted by HAM_RADIO_MAN View Post
There is a bolt head right under the clamp that will cause you a lot of frustration. Open it up and get it around the up pipe behind the flange with the opening pointing down. then slip it over the flange and rotate it around the correct direction with the opening on top and tighten down. I didn't remove my manifold and mine just fell right on.
GOOD LUCK.
Well I tried everything and after many hours wasted today I finally got it back on. I unhooked the EGR exhaust down pipe from the exhaust manifold and the large turbo pipe and had a friend pull them as far out of the way as possible. I could then finally finagle the clamp back on. Once back on it was just a matter of hooking everything back up. What a pain in the arse it has been. I expected something to go wrong since everything else went so smooth replacing EGR and oil cooler. Truck fired right up and ran smooth. Took it for a ride and let it heat up, all sounded and ran good. Came home and fired it up after it was run at operating temperature and started right up. I hope this was the only hiccup. Thanks for the suggestions.
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