EGR Up Pipe Delete Homemade

[oxman202]

Ok, this is my first write-up so here it goes. You need another pair of hands for this project.


Parts needed:
Freeze Plug Dorman Part# 555-077 I got mine at O’Reilly for $0.69
Up Pipe Gasket Ford Part# 3C3Z-6N640-AA
A Piece of 1 3/4" Pipe
A Piece of 1/8”x3”x2 3/4" Flat steel
WD or your favorite lube

Tools Needed:
Welder
Grinder
Hammer
3/8” 13mm deep socket
1/4” 11mm deep socket
1/4 ” 10mm short socket
2x 3” 1/4" extensions
2x 10” 3/8” extensions
5/16” Nut Driver
5.5mm Nut Driver
Flathead Screwdriver
3/8” ratchet
1/4" ratchet


1)First take the passenger inner fender out.


2)Then spray your lube (haha he said lube) on the bottom and top nuts and bolts.


3)Loosen the Vclamp on the turbo down pipe. Take the down pipe and remove it. If you have the stock down pipe like I do then you need to take the transmission cross member out. The easiest way I found was to loosen the two nuts to the tranny mount and use a jack and some blocks of wood to jack up on the tranny pan about an inch and put a jackstand under the tranny. That way when you take the crossmember out all the weight is off of it.


4)Next take the two bottom nuts on the up pipe and loosen. The nuts are 13mm and the bolts are 10mm.


5)Loosen the Vband clamp that holds the EGR cooler to the exhaust.


6)Loosen the nuts on top of the up pipe.


7)You will be able to take the up pipe out from the bottom by bending the tab that holds the inner fender out a little.


8)Weld the freeze plug in the EGR flange. make sure that you have the part number facing out. There is a small lip on the EGR cooler itself. If you get to much weld on it and it doesn't seal all the way it's ok, you can use a die grinder to grind the inner part to fit it


9)Cut the EGR flange off close to the flange as possible.


10)Cut the rest of the pipe off of the up pipe and grind down the weld that was holding it. This takes some time and patience.

11)Next take and tack the plate of steel to the 1 3/4" pipe and hammer it around the pipe.

12)Test fit the plate on the up pipe; you might have to bend it out a little to get it to sit just right.


13)Start by tacking then fully weld it up. Clean it all up a little.



14)All you have to do now is just put all back together.

[oxman202]

Here are some more pics. Look at the difference in the old and new gaskets. The new gasket is a two peice. There's a pic of the inside of the up pipe to show the penetration of the welds. If there is any thing that I left out let me know.

[Evil Eye]

Oxman,
Pretty good write-up... Since you have the 03, did you have a scoop in your up-pipe?

[oxman202]

Thanks I have to do some editing. No scoop. I'm pretty sure that if it did have the scoop; the way I grinded it down it would have came right out from seeing other pics.

[mschn99]

on an 03 you can just press a freeze plug in the pipe.......you dont need to cut it like that since there is no scoop.

The later ones are the only ones that would actually need your modifications...

fit freeze plugs in all of them.

[oxman202]

Originally Posted by Marc

on an 03 you can just press a freeze plug in the pipe.......you dont need to cut it like that since there is no scoop.

The later ones are the only ones that would actually need your modifications...

The freeze out plug sat in the pipe a little loose so I welded it in there. I think pressing it was out the question. I thought it might flow a little easier without the extra tube making turbulence. It didn't take that much more work to do it the way I did it. Also you don't have any conductive heat transfer being the pipe is completely gone. But just the freeze out plug would do fine. I just like doing the best I can.

[DoubleDpsd]

solid write up. I'm gonna have to listen to marc and do the freeze plug idea. hopefully we can take it somewhere the day we do it and have it welded in place. Save me $165 I would have spent at elite. Lookin' forward to seein' ya in december marc. check ur pm's doood.

[Evil Eye]

Originally Posted by oxman202

Thanks I have to do some editing. No scoop. I'm pretty sure that if it did have the scoop; the way I gringed it down it would have came right out from seeing other pics.

Looks much better now, bud! Great job!

[oxman202]

Originally Posted by Evil Eye

Looks much better now, bud! Great job!

Thanks, Marc helped me out with posting the pics better. He also told me he's going to put it the tech files.