6.0 EGR Delete bad to worse - Ford Powerstroke Diesel Forum
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Old 02-27-2014, 08:17 PM
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6.0 EGR Delete bad to worse

Just a quick story to share. Feel free to laugh at my misery haha. So started off as any EGR delete goes, pulling most of the top of the engine off and it goes smoothly other than a few sockets dropped into the pits lol. Turbo comes off and up pipe comes off the Y pipe. Staring to get at the up pipe from the exhaust manifold and snap both bolts off in the up pipe . Next we try applying heat and beating the hell out of it . Still nothing. So then to get better access tire and wheel well liner come out and break half the damn pine tree clips on the way out. After more ruthless heat and beating we decide to take the exhaust manifold off and after 20 minutes of PB Blaster soaking it comes off fine . Then we buzz the bolts off and go to drill them out of the exhaust manifold flange. 5 broken drill bits later one is still stuck in there. Hands down the absolute worst rust weld i have ever seen, that bolt would not break free. But eventually did. And props to the rust that was a damn good weld job! So next smooth sailing intake manifold goes on and is finger tightened. I begin torquing down the front bolts but my self forgot I already torqued the ones that hold the EGR delete down so i snapped the one and had to take the intake back out and am on my way to the dealership tomorrow to get a new stud. This isn't that bad of a scenario I know so much more could have gone wrong but I felt as though i would just share it for sh*ts and giggles. Good luck to anyone else doing projects as mine should be done tomorrow.
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