Need help with full EGR delete - stripped top exhaust on lower cooler - Ford Powerstroke Diesel Forum
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Old 03-26-2014, 07:07 PM
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Need help with full EGR delete - stripped top exhaust on lower cooler

Not sure if this is the right forum, also did a search and didn't find a solution. Here's my problem. I'm doing the EGR valve and cooler delete, and I'm using Sinister's kit. Also installing Sinister's coolant filter and Flo-Pro intercooler pipe at the same time. Everything was going smoothly, parts coming off as they should, new parts going on as they should. Got to the last bolt on the lower EGR cooler - the top bolt on the exhaust side. Sure enough, the head stripped. I use PB blaster, heat, you name it. I can't get it to come loose. I finally quit for the night and will tackle it tomorrow. What do you guys suggest to get this b@st@rd out?

Secondary question. Since the EGR valve and all it's plumbing are gone where do you suggest I tap in to hook up the coolant filter. The only lines left are into the Y pipe and the Degas Bottle. They are much bigger than the Tee's provided by Sinister.

Any help or suggestions are greatly appreciated.
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Old 03-27-2014, 05:06 AM
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Not sure on the stripped head on the bolt.
But my instructions on the Sinister coolant filter said to use the lower heater hose behind the air box.


Spock
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Old 03-27-2014, 05:43 AM
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check this thread
EGR Delete-Full Install (Long+Pics)
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Old 03-27-2014, 07:00 AM
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I did the exact same thing when I was removing mine, ended up getting my dremel in there with a cutting disk and going to town cutting it off. The bolt treads into the EGR cooler side so you will just have to get a new bolt if they didnt send it in the kit like I had to.
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Old 03-27-2014, 07:31 AM
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Nice tip on the dremel. Now that I've had a night's sleep and a cup of coffee I'm going to go that route.

Now, if I could only find my dremel!!!
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Old 03-27-2014, 07:32 AM
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Spock - thanks for the reply. Didn't even think to read the instructions, duh!
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Old 03-27-2014, 07:15 PM
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Quick update: Dremel did the trick. Only took 45 minutes and 26 discs. I now have a permanent imprint of the hood latch on my left inner thigh, but I finished!

I deleted the EGR valve and coolers, installed the Flo-Pro intercooler pipe, installed the Sinister coolant filter - and it only took me 11 hours total (of which 3 hours was getting the last bolt out of the lower cooler).

Glad that's finished. I can understand why shops want $800 - $1000 labor for that job.
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Old 03-27-2014, 07:26 PM
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Sounds like the same bolt that gave me some grief too. I did if from the wheel well though so no imprints on me!! lol
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Old 03-30-2014, 05:54 AM
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Yup! Same thing here with the bolts! Ended up with an air chisel in there to pop the heads of the bolts off. 2 hours of extra time. 10 hours total time with tuneing and checking it over for any kind of leaks after the install. The outcome.........A CLEAN AIR BREATHING MONSTER
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