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Installing a Thermocouple

2K views 19 replies 7 participants last post by  CSIPSD 
#1 ·
This weekend I'm going to install the thermocouple and my Edge CTS. I'm new at this and looking for techniques and helpful hints.

When drilling the hole:

1. Best way to make sure the hole is straight? Bracing?

When tapping the hole:

1. Looks like the best technique is to go in 1/8 of a turn and then back the tap out to clear debris. Repeat. Then, once complete, run the tap back through the whole length 2-3 times. Any better way/suggestions?

2. Do I thread the entire hole all the way through?

3. Is Loctite or anything else required to secure the thermocouple?

Lastly, if I SCREW THIS UP...Any large amount of damage if I drive 10 miles to a diesel mechanic with a small hole in the manifold?
 
#2 ·
Just make sure your location allows enough room for the probe itself. When drilling, use lots of grease to help catch the metal shaving from going into the exhaust. Do the same with the tap. Go in 1/8-1/4 turn and then back it out the same... Just keep repeating. Once your get close to going thru, then unscrew the tap all the way, clean it off, clean the hole out, and then regressed and finish tapping all the way into the exhaust. If your really nervous about it... Some guys say do it while the truck is running so there is pressure pushing towards you keeping the shaving from entering the exhaust, or you can use a magnet after your done to try and get all the little pieces one your done. It's not hard though...
 
#3 · (Edited)
It's not as hard as it seems, yes it's alittle scary drilling into your exhaust manifold. You have plenty of room when drilling, where a really good pair of safety goggles that wrap around your face because ounce you start drilling the metal shaving plus the carbon thats inside the manifold falls everywhere, you DO NOT need too use grease, you are drilling into the bottom of the manifold so the shaving will fall onto you and the ground. When tapping the threads start then back out allowing the tap threads too stay clean, do this a few times, and remember a NTP is slightly tapered, so you don't have too run the tape all the way in, the hardest part for me was getting the fitting started, it took using my thumb appling pressure while using a open end wrench to start the fitting. You need too use some type of anti-sieze grease on the fitting and the probe threads. One other thing I did was tooke my shop vac and made a tight fit over the area and vacuumed out whatever might have been inside the exhaust, here is a pic from Diesel Manors web site, plus there are several more that are very detailed on installing the probe. If you read the comments with the pics the guys at diesel manor go into better detail on why you do not use grease, and like I siad there are more pics than just this one.

3-Gauge Install Pictures
 
#4 ·
Drill, tap, install. Don't grease, don't step the bit size.

Unless you live somewhere that Obama has turned off gravity, 99.9% of the drill shavings will fall in your eyes, face, armpit and such. Any shaving that does fall UP will blow right past the turbine wheel without issue.

Drill, tap, install.
 
#5 ·
To each their own... I've seen multiple guys use grease. Doesn't hurt anything to be extra cautious :thumb:
 
#7 ·
Greasing is not being extra cautious and can cause problems; greasing is more like being extra reckless. What originally would have just fell out on its own will now not fall out and clump all up. Then you have more than just a couple tiny peices to blow through the turbo
 
#6 ·
Question is..

What does it help? Drill bits are designed to eject material, gravity is designed to let objects fall.

Greaseing the bit defeats both.

I've installed countless pyros... drill tap install.
 
#9 ·
I stepped the drill bits when I installed mine. It is a little nerve racking drilling into your manifold cause if you mess up, you pretty much need a new one. But all I did was drill it, tap it, and put a vacuum cleaner up to the hole to suck out all the shavings that were still in there. Not as hard as it is made out to be.
 
#11 ·
I do leave the keys in the ignition when i install my tunes, cause the key needs to be on! :hehe:... Unsubscribed
 
#12 ·
See ya then. Atleast we no longer have someone in here telling to OP to do something wrong. Maybe grease is ok in a garbage 6.0 like you've got, I don't know... There's not much more you can really mess up on those so I can see why your opinion is as is
 
#13 ·
Installed!

1. Didn't use grease.
2. Did step the drill bits 1/8 to 1/4 to 21/64.
3. Learned my lesson about a cheap tap kit. The handle was CHEAP and used a socket wrench instead.
4. At the end, after a shop vac, there was almost nothing to get out with a magnet.

Things left to do...
1. Test drive when football is over.
2. Next is fuel press, trans temp, and boost...
 
#14 ·
Glad you got it installed right. I hated the tap that came with mine too where you had to use a socket, but it got the job done.

Trans is super easy. Be sure to check with leaks in the fuel pressure and put it in the port on the passenger side so you get post filter pressure. For boost, I'd reccomend doing the AIH delete and putting it there, that ones real easy too.
 
#16 ·
Even easier than the intake heater plug is T-ing into the mass airflow sensor line. Quick cut with a set of sidecut pliers and a couple hose clamps is all it takes.
 
#17 ·
There is no mass air pressure sensor on the 7.3...

There is a manifold air pressure sensor...

If you T into the line be sure to use quality brass fitting so it doesn't leak.
 
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