EGR cooler hose replacement - with pictures - Diesel Forum

GregH · 10-08-2007, 03:51 PM

Here is how to replace the orange EGR cooler hose without removing the intake manifold or EGR cooler.

Start by identifying the leak. This leak is usually present for a short time after the engine has fully cooled down. A few drops of coolant will appear to be dripping off the lower rear corner of the right cylinder head.

Look for coolant below the orange hose

If you've got coolant here, then take out the turbo and pedestal.

Turbo and pedestal out

Drain out some coolant, so when you disconnect the EGR cooler hose you won't dump coolant everywhere.

Turn the hose so the "1" symbol is straight up
Slide the hose straight back
Have these two o-rings on hand
Note: the cover may be a bit difficult to get off. Work it side to side to keep from breaking anything. If you get medieval with it, the cover will break.

Install the two new o-rings along with your new EGR cooler hose (it will be blue) and put 'er all back together...

Beer time...

weasel79 · 10-08-2007, 05:37 PM

Another one for you! Ill get the first case! LOL

AllOutFirefighter13 · 10-10-2007, 04:57 PM

<span style="color: blue"> Greg ,

Awesome right up...you never cease to amaze me. Your contributions are a true asset to TDS!

Later, </span>

04txdiesel · 10-20-2007, 08:27 PM

Any chance you know and could post up those part numbers?

Thanks

Stewey · 10-24-2007, 02:16 PM

Greg,

How much coolant debris/grunge do you guys normally see when you remove egr and oil coolers?

edub32 · 10-24-2007, 07:41 PM

yeah can we get some part numbers for the new hose and orings please

fast72lemans · 01-21-2008, 07:58 PM

I've noticed this since the temp dipped into the teens, What kind of time are you looking at to replace the hose and seals? It's funny but if I plug the block heater in, it doesn't leak.

dsltek · 05-03-2008, 12:14 AM

orange egr hose now blue....basic part #8592 dealer will knw.....the housing that hose connects to 9p456.......btw i do them all day long 20min only remove the cac tube!!!!
pbeu135@hotmail.com

Fordjunky10 · 05-03-2008, 09:33 PM

if your good you dont have to take the turbo or pedestal out

dsltek · 05-05-2008, 04:39 PM

oh no turbo no pedestal jst the cac tube and an arsenal of choice weapons lol

357sparky · 12-08-2009, 04:14 PM

Is there a trick to removing the egr supply housing. have the cover off and can move the housing with alittle help from a couple of pry bars (gently) but it doesnt want to come straight up.THX

357sparky · 12-08-2009, 04:35 PM

never mind GOT IT

toddwfli · 12-09-2009, 06:26 PM

I had the same problem. I put the hose on the housing first before I put it back on. This worked the best for me, I could not get my fingers around the hose. I have not seen anymore fluid on below 25 DEG days.

skrub67 · 12-10-2009, 07:19 PM

Holy batman... Just spoke to my local dealer.. they want $400...I say again, $400 to replace the EGR cooler hose...I already have the hose, coolant and gaskets that go to the little housing that the hose hooks up to opposite the EGR cooler. I about hit the floor.

I think I will try this repair myself....I hope it turns out well...lol

eazrider · 12-19-2009, 12:49 AM

Quote:

Originally Posted by Fordjunky10

if your good you dont have to take the turbo or pedestal out

My hose appeared to be intact, but the cheap clamp Ford used didn't seem to be tight enough. I cut the old clamp off (without removing the turbo) with some diagonals and slid a regular hose clamp around it, snugged it up, no more leak...(did get a charley horse in my hand from contorting it to thread the hose clamp together...)