EGR exhaust cooler leaking

Shadow_Grey

Shadow_Grey

Comfortably Numb
Joined
Aug 21, 2006
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57
My brothers Excursion is leaking and we are going to have to tear it down one of these days and replace/repair it. Path from exhaust to cooler is already welded up and now the dang thing is leaking. Another Saturday shot digging down to the cooler again.

Anybody have a replacement for it that is better than the crimped tin can POS?
Can we take it off and block the coolant out the head?
What have you done?
 
I guess, I need to see how the stock one is on there first. Then see how we can eliminate the coolant flow thru the cooler, if possible. I think you just eliminated the exhaust thru the cooler, correct, or am I not seeing the cooler? Welding the exhaust pipe and making a flange for the input to the intake. What about the coolant lines?

I'll figure something out to stop the leak ie eliminate the cooler.
 
hey shadow... sorry to get off the topic, but what Bilstien shocks did you change to and do they make a difference in the ride. these things ride like tanks without a load and im looking to soften the ride a bit....your thoughts would eb appreciated
 
Don't go with Bilsteins if you think it rides rough now. I am thinking about taking mine off as it rides worst than before. All I changed was installing the 2.5" blocks leveling pads in the front and put 350 blocks in the rear and added the shocks. I get the constant rocking back/forth and jiggleing.
 
Thanks Weweld.
I think we got it. We'll have to pull the intake also, correct?
That is where the flange goes after removing the cooler, right?
Then reroute the coolant line the way you have yours?
 
thanks Grey... I have the leveler already in by the dealer. i am just trying to not have the change bounce out of my ashtray and my coffee spill all over my truck when i drive down the highway... any suggestions from anyone??
 
Is the elbow on the bottom side of the intake part of the old cooler? Been thinking about removing mine as well. Thanks for the pics Weweld:ylsuper:
 
I cut this fitting out of the cooler

http://www.socaps.com/photopost/showphoto.php/photo/4324/cat/21013

I then cut the pipe off the other end of the cooler

http://www.socaps.com/photopost/showphoto.php/photo/4328/cat/21013

Then welded these two pieces together

http://www.socaps.com/photopost/showphoto.php/photo/4327/cat/21013

To look like this

http://www.socaps.com/photopost/showphoto.php/photo/4329/cat/21013

Then take the flange with the threaded holes and cut it off and weld a plug in it

http://www.socaps.com/photopost/showphoto.php/photo/4324/cat/21013

It should then look like this

http://www.socaps.com/photopost/showphoto.php/photo/3975/cat/21013

Then bolt the flange to the manifold put the welded pipe fitting in the manifold and cut a tab to weld the two pieces together like this

http://www.socaps.com/photopost/showphoto.php/photo/3974/cat/21013

Then install the manifold and put on the hose like this

http://www.socaps.com/photopost/showphoto.php/photo/3972/cat/21013

You can leave the EGR valve in place and connected if you like it makes it look good at first glance.
 
so... not to be stupid, but i don't understand.. what is the reason for an EGR Cooler delete... and do you guys run your EGR on your daily drivers or does it just take power away??? thanks for helping out the new guy
 
Gene, how much crap needs to be removed in order to finally remove the manifold to do that mod?

Is this something where the cab needs to come off?
 
I did mine with the cab off but it can be done with it on. as long as it is not an 03 the turbo will not have to come off. Not real sure what else if I get a chance I will take a look and see if I can help you out.

jmanF250
We did the EGR delete for racing purposes but it is also done on daily drivers to cure a number of drivability problems.
 
thanks WE WELD.... i am kind of a novice.. just trying to figure this all out. i have heard that it is better to run with the EGR removed or unplugged...on a daily driver, is that true...thanks again
 
The best thing to do is have your tuner turn the egr off on your programs if you're running SCT. But completely eliminating it like Weweld did would be the best thing to do. Just don't expect to get any warranty work done :doh:
 
We are getting some parts from the junk yard and welding them up ahead of the actual teardown time.
 
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