Head Gasket Blues

[browndog]

I'm well into my head gasket repair and would like to report how much this job sucks. Being the relative clod that I am I've already broken three things, two of which I can repair but the last one is a major issue. While trying to loosen the union nut to the EGR valve (having PB blasted it the night before) the threaded nipple from the EGR cracked.

Super.

The problem is that some of the threads are still in the union, frozen by rust and 14 years worth of neglect. How in the world can I get this out? There aren't enough threads to grab with a vice, and the stuff is pretty brittle.

Also, I would like to mention that the bolts/nuts holding the upper air intake from the lower were not NEARLY as difficult as the two bolts closest to the firewall that hold the lower intake to the head. I got one of them out by nothign short of a Houdini act, but the last one is KILLING ME. WTF!!!!!!!!!!!!!!

 

[darmaduke]

My truck is not here right now, but I think you are talking about the big nut connecting the EGR to the piping that runs down to the bottom of the head?? i am trying to remember, i can't run out a see as its getting a inspection right now.

BUT... I left that on, and took the whole thing of on the bench as it is attached to the head anyway, just undo the two studs holding on to the manifold. (remeber to put it back on before you put the head back, or you cant get it done up.

As for the bolt, I had to use a wrench from the top, just 1/4 turns at a time.

ONE thing to do....... when you get the head out, BE VERY CARFUL OF THE KNOCK SENSOR. the intake manifold will rest right on it when you pull it out of the way, they are very fragile and 250 a peice. (I know I broke one of them.)

i would take it out right away and put it back in later,

good luck.

I just did two of these back to back....lol

Scott.

 

[Ruadhrigh]

BUT... I left that on, and took the whole thing of on the bench as it is attached to the head anyway, just undo the two studs holding on to the manifold. (remeber to put it back on before you put the head back, or you cant get it done up.

Scott.

This is good advice. Just be gentle with the Torx socket. This project seems daunting at the beginning. But when you go to put things back together it all flows and is not as frustrating.

 

[browndog]

I think you guys are misunderstanding my issue. To help with this I will post a pic ASAP. Thanks for the replies.

 

[browndog]

Here is a pic of my problem. As you can see, the threaded nipple which comes off the base of the EGR valve cracked, leaving part still threaded in the union.

Am I really the first person this has ever happened to? How can I get this thing out?

Man I'm missing the simplicity of my 60 right about now.

 

[locrwln1]

Ummm, wow. Don't know what to tell you about that. On my LX, the EGR came apart with no problems, sorry.

As far as the last bolt on the upper/lower manifold, have you tried from the bottom, lying under the truck? It's been a while since I did mine, so I may be wrong about that one.

Also, after breaking mine, definitely remove the Knock Sensor.

Good luck, believe it or not, it seems to go back together easier than it comes apart.

Jack

 

[Ruadhrigh]

That piece of the EGR doesn't matter right now. That pipe is connected to the head, and you can remove it after the head is out. If you can't get the piece out after the head is out, give it to a machine shop. They'll make short work of it.

 

[OGBeno]

Just replace. Call it a day and move on. No use in worrying about small things like this on a big project like the one you are working on.

-o-

 

[LX_TREME]

As others have said Browndog, that's nothing.You already broke it and move on.Keep on going pull them out.

 

[darmaduke]

I would just move on as well, the union will be attached to the head, take the head off, take the pipe of, and either take it to a shop, as sugested, or get a new pipe and EGR valve....

I did not touch my valve, for this very reason, it was not comming apart with out a fight, once on the bench I freed it up.

i will mention it again, watch the Knock sensor... very exspensive, very breakable.

good luck again.

scott.

 

[GeoRoss]

That isn't a problem really. You will need a new EGR valve for sure, the union/down pipe is probably still workable.

 

[Ruadhrigh]

Browndog,

Looks like you did a good job PB blasting that thing. Rust sucks. I was lucky and had none, but Beno's truck is full of it. Did you have problems with anything else yet?



LX_TREME,

did you put the cams back in after the head was out? I love seeing pictures of the head and cams

 

[Photoman]

Take the blade of a hacksaw (just the blade) and in a gloved hand saw through the nipple part in two or three places. Then take a punch and knock the pieces out hitting them inward toward the center. When sawing try to be as careful as possible when cutting so as not to cut too deep into the threads you are trying to preserve. If the hacksaw blade is too wide to fit into the hole I have ground them down a little at a time to not overheat them to size them to fit. A lot of work but might help you out.

Bill

 

[Mark Davis]

Browndog

Have you tried an easyout.

 

[browndog]

Thanks for all the replies fellas. I have continued to work on the project but just wanted to know how catastrophic this was. Looks like it really isn't a big deal.

I should have the head off tonight and will get started on reassembly tomorrow. WEEEEEE!

 

[Ruadhrigh]

while you are there. take off the oil cooler and clean it out. Really easy to do and you have tons of access with the manifolds out.


You never know what you might find.

 

[Ruadhrigh]

Here is what I found inside my oil cooler:

 

[powderpig]

That last pic is only the cooling area of the oil cooler. Just so some folks do not get so worried. It is not the inside of the oil cooler. It may just mean that the cooling system was not serviced very well in the early years. later Robbie

 

[Ruadhrigh]

Very true. I didn't actually diassemble the oil cooler, but I did seperate it from the block.


Beno's truck wasn't as nasty but he did some sediment.

 

[OGBeno]

Beno's truck wasn't as nasty but he did some sediment.

Relative to your's, mine was clean.....

I separated the cooler apart and all was good inside. Nice and clean.

Relating back to the OP's predicament, again, it would seem wise to just keep trucking with the tear down and just get a new pipe and EGR valve and put things back together.

I don't think you want to waste too much time here.

-o-