Doing The EGR Deed

[Alan Reagan]

What a PITA with the hidden bolts on the EGR cooler. Last night, I finally got the two inside nuts off. Let me correct that. The studs came out with the nuts. Both nuts are cross threaded. This is the first time they have been off. Must have been a bad day at Cummins.



I called the dealer. $40. 00 for the studs and nuts. I went to all the part stores and couldn't find stud sets that length. I tried a nut cutter. No joy. I was just going to replace the nuts. Since I have extra time, I've done the throttle body, butterfly valve, CCV filter and everything else I can see that needs some attention. I may have found a solution to the hidden nut problem. I will post again tomorrow after I put it back together. I went to all of the local parts stores. NAPA had the closest replacement studs and they were class 5. Apparently, the OEM studs and nuts are a soft alloy, non magnetic (read plated brass). At least my magnet won't grab them. I'm ready to be done with this. I would think the dealer would carry them in stock instead of ordering them all the time. I may use the class five bolts with anti seize. The OEM bolts are too soft and round off with the first slip.



The kicker is, most of my miles are highway and the cooler and butterfly were not as crushed up as I thought they would be.

 

[RDick]

Alan, how did you remove the 15mm nut that hold's the EGR cooler onto the exhaust manifold, the one next to the engine block?

ron, up the road,Hiawassee,Ga.

 

[Alan Reagan]

With a crows foot 15 mm. The the stud came out on that one. Be very careful. If you go ahead and separate the butterfly valve, you can see it and get to it with the crows foot. If you have a 15 mm 1/4 drive socket you may be able to get on it. Here's the best tip... As you remove something, put the bolt back in the empty hole. You will know what I mean when you put it back together.

I PMd you back. Call. I just finished and fired up the truck. All is well.

 

[mwilson]

This is what one of my top Cummins Techs has for the 15mm nut. He goes in from the rear of the cooler with the wrench. We DO NOT KNOW if there is clearance in the RAM pick-up as we are working on the 6. 7 engines installed in Freightliner medium duty trucks.



The wrench is made by E-Z RED, he bought a complete set of these through Sears. Part number for this particular wrench (13mm x 15mm) is EZRRM1315.

 

[mwilson]

This wrench is looooooong, almost 16".

 

[RDick]

Wow, what a wrench. Tried using a clawfoot but it only slipped off. I will send photos of the location of this 15mm nut. With Geno's "Perform Service" at, 67,500 miles, page 8, (Remove two 15MM nuts that hold the EGR cooler onto the exhaust maniford. Yes, they are hard to reach. ) The nut towards the back, closest to the block, is the one I can't remove. I have never sent photo's on the site, but will try.

Thanks all,
Ron

 

[Alan Reagan]

The flange on mine appears to be rotated 90 degrees from yours. No wonder you can't get to it. You may need one of the new Craftsman ratchets where the socket slids into the ratchet leaving the hole open for the stud. That wrench should work. Those wrenches are available at Lowes and Napa. Take a couple of more pictures. That looks like the front inside bold on the butterfly valve. Apparently my bearings are off here. Where is the picture taken from?

 

[RDick]

Error! I had said I was on page 8, but acually I was on page 6. On removing the two 15mm "nuts"? Geno's sheet says "bolts"; this through me off as they should be written as "nuts" for my 2007. 5. They may have changed to "bolts" after my year. I used a flexed Craftman wrench, as pictured, which is shorter than MWilson's. I used a 15" adjustable wrench on to the open end of the flexable wrench, and it finally broke loose. Now back to page 8 . . . . wish me luck

Thanks to all,
Ron

PS: Allen, I will let you know how I do.

 

[rashwor]

Looks like a PITA.

 

[Alan Reagan]

It is a big PITA.

 

[RDick]

Finished the "Perform Service". I will agree, it is a BIG PITA!! But, with the correct tools and following Geno's instruction sheets, except for the 15mm nut rather than bolt and (under part 2) never mentioning the gasket for air horn-to-intake manifold which was included in the kit, anybody can do this maintenance procedure. Thanks for Alan's help who was there everytime I called him, and to the other TDR members for their input . . . and my wife for crawling up on the engine to get to those nuts on the exhaust manifold . . . this 74 year old TDR member is very grateful.

Ron

 

[Alan Reagan]

You are very welcome, Sir. I enjoyed talking to you each and every time you called and I'm glad it worked out. I thought I was going to get me a trip up to Hiawassee. I love it up there. If you are ever coming throught the cultural center of the universe (Kathleen, GA), let me know. I would love to meet you and your wife. She sounds like a good sport. You, too. And good for you taking on the challenge of the EGR Cooler cleaning operation.

 

[GCP]

Finished the "Perform Service". I will agree, it is a BIG PITA!! But, with the correct tools and following Geno's instruction sheets, except for the 15mm nut rather than bolt and (under part 2) never mentioning the gasket for air horn-to-intake manifold which was included in the kit, anybody can do this maintenance procedure. Thanks for Alan's help who was there everytime I called him, and to the other TDR members for their input . . . and my wife for crawling up on the engine to get to those nuts on the exhaust manifold . . . this 74 year old TDR member is very grateful.

Ron

You are very welcome, Sir. I enjoyed talking to you each and every time you called and I'm glad it worked out. I thought I was going to get me a trip up to Hiawassee. I love it up there. If you are ever coming throught the cultural center of the universe (Kathleen, GA), let me know. I would love to meet you and your wife. She sounds like a good sport. You, too. And good for you taking on the challenge of the EGR Cooler cleaning operation.

These two posts above are exactly why I'm a member of TDR. The level of support backed by a genuine sense of camaraderie always play into my membership renewal. Further, you guys have convinced me that I can perform my own 67,500 mile EGR service.

Thanks,

GCP

 

[Alan Reagan]

GCP, If you have any problems, give us a call. I would much rather tell somebody how to do this and have to do it again. :-laf



Just take your time. And when you read the part in the instructions that says "there are several bolts" holding the cooler line on that have to be removed, mine only had one. But I'm still looking.

 

[RDick]

Alan was a big help, as are all the member's. Issue 81 page 68 thru 70 has alot of great info, wished I had read this before starting. Have the right tools and like Alan say's "take your time".

ron