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EGR cooler leak question

Discussion in '40- & 55-Series Tech' started by hooter, Mar 4, 2017.

  1. hooter

    hooter

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    '77 FJ40 mustard

    The EGR cooler has a pretty substantial leak where the cover meets the body of the manifold.

    IMG_0759.JPG

    Is it possible to replace just the cover or do I need to replace the whole EGR cooler?

    Searched and found several issues wth 'the big nut' and sheared bolts in removing the cooler.

    Any advice appreciated in fixing this fairly large exhaust leak.

    hOOter
     
  2. Pin_Head

    Pin_Head

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    It is probably just as easy and expensive to replace the whole enchilada. It may be easier to pull the cooler along with the manifold assembly and get a new manifold gasket.
     
  3. hooter

    hooter

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    Interestingly, I found the leak on the tail end of exhaust manfold gaskets change.

    I just replaced (today) exhaust,intake riser gaskets and doughnut. As I was tightening down the doughnut I looked up and found this monster hole from the underside of the EGR cooler.


    I can take it all apart again but would like to avoid if possible. I'm smart enough to listen to wise people, so if that's the easiest way, I'm
    game.


    If possible to do without pointers are appreciated.

    Thanks for your advice

    hOOter
     
  4. Pin_Head

    Pin_Head

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    The big compression nut is often a PITA necessitating some hefty tools that you can't fit with it installed.
     
  5. hooter

    hooter

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    Understood.

    Thx for your help.
     
  6. LAMBCRUSHER

    LAMBCRUSHER

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    A large crows foot might work for you there
     
  7. hooter

    hooter

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    Is it possible to remove the cooler with the pipe attached? Unbolt the egr pipe at the manifold with its 2 nuts and slide it out as a whole unit? My guess is that the nut and pipe won't clear the manifold rigidly fixed from up above.
     
  8. LAMBCRUSHER

    LAMBCRUSHER

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    I have done on my 55 several times, yes. you might need to loosen the steering box from its mount to gain some room. it IS a pain, but it can be done...But @Pin_Head is right...I am refurrbing my fj60 emissions junk, and trying to get everything cleaned up enough to be able to bolt it together nicely(cleaned threads, new flanges, might need custom compression feruls, new longer studs). even with all threads able to bottom by hand, it will still be near impossible to affect a crushed connection with all the other gear in the way{near}). I have not ruled out lifting the engine/trans/tcase out to mount the crap.
     
  9. hooter

    hooter

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    Im not an idiot.

    If 2 wise people are cautioning me to do this the right way.....I'll listen.


    Too many horror stories of broken _____ to do this wrong.
     
  10. hooter

    hooter

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    UPDATE

    PITA is an understatement.

    The big nut/j tube and egr valve have been removed.

    Taking the unit off the truck was the only way to do this. I had to heat, soak, percuss, heat, cut , cuss, heat, soak.....finally.

    IMG_0991.JPG

    Thank you @pin_head and others for the sage advice.

    Now on to the reassembly....
     
    Last edited: Apr 1, 2017
  11. oldschool4wheeling

    oldschool4wheeling SILVER Star

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    Did you find a replacement EGR cooler?
     
  12. hooter

    hooter

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    Yes.

    Got a used one from Cruiserparts. Its rusty as hell and looks worse than the one I have (except no holes- which is the point of this exhaust leak debacle).


    hOOter
     
  13. oldschool4wheeling

    oldschool4wheeling SILVER Star

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    I was going to offer to sell you mine. But I'm not sure if a 79 is compatible to 77.
     
    Last edited: Apr 1, 2017
  14. 65swb45

    65swb45 Supporting Vendor

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    FWIW, I took a piece of 3/8" bar stock (think shackle plate) and made a crowsfoot wrench for the reassembly phase.

    Best

    Mark