EGR Delete/Removal Troubles - Ford Powerstroke Diesel Forum
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Old 01-16-2013, 08:30 AM
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Angry EGR Delete/Removal Troubles

So I set off on the EGR Cooler delete/removal and it hasn't gone well. I removed the coolers and removed the vertical EGR bracket with minimal problems. I then removed the horizontal cooler with minimal problems. Then I get to the horizontal cooler bracket........ Sh!t, Damn, Mother Freaking Son of a Beehive. The last bolt head "bottom rear" strips out. I'm screwed!!!
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Old 01-16-2013, 08:38 AM
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Sorry to hear. You'll be glad to know that this is somewhat of a common problem. There are several different people that have shown what they did to fix the problem. I'll search for a couple links and post them in here.

EGR Delete-Full Install (Long+Pics)

Last edited by fordpwrstroke7; 01-16-2013 at 08:44 AM.
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Old 01-16-2013, 08:42 AM
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I purchased Craftsman's "Bolt Out" socket kit. I'm hoping that this 10mm P.I.T.A. comes out. This bolt is at a bad angle and tight spot. GRRRRRRRR
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Old 01-16-2013, 02:01 PM
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Finally got the Manifold bolt out
Installed Flo-Pro Intake elbow, Rudy's EGR Delete
Waiting for the updated Upper Radiator Hose and some Intercooler hose clamps.
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Old 01-16-2013, 05:19 PM
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What did you do to get it out? I'm sure others could use the info, including myself, later on.
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Old 01-16-2013, 06:16 PM
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The lowest bolt on the manifold is best removed from underneath the truck. I used a 3/8" Drive Socket wrench and a 10mm Snap-On Shallow socket. If you have a second set of hands they would be great from up top of the engine bay to help steady the wrench. If you keep the socket centered on the bolt head, it should come out with a little bit of torque. Be sure that the bolt head is clear of rust and debris. This was the main problem I ran into. I thought I stripped the bolt head while trying to remove it in the engine bay. Upon inspecting the bolt head from under the truck I noticed rust so I blew that area off with a blow gun.

Some extra tips and pointers to ease the removal and installation of EGR delete kits.

*2 sets of hands and eyes are a plus!!
*liquid wrench, air tools, impact wrench, nice box wrenches and patience
*adequate lighting
*Drain Radiator Fluid properly and check for contaminants
*I loosened the Front/Top Radiator support for more room to work
*Cover Intercooler, and other coolers while working around the engine bay
*Remove the drivers side wheel well shroud
*Work your way from the top of the motor down
*Segregate and organize nuts, bolts and parts and label them if you have a bad memory!

If anyone has any other questions or concerns let me know
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