How Difficult is Replacing EGR Tube on 93 3.8 Ford Taurus

[GaryYarber]

I am working on a 93 Ford Taurus 3.8 engine. The metal nipple broke off of the EGR tube. There are two nipples on the EGR tube attached to hoses which run to the DPFE sensor. The lower nipple is the one that broke off. How difficult is it to replace the EGR tube? Does anyone know the steps involved?

Also, as a temporary measure, I capped off the orifice on the DPFE sensor which had the hose on it which had been attached to the lower nipple on the EGR pipe before the nipple broke off. Now the car is jerking when you drive it. Could capping off the orifice on the DPFE sensor be causing the jerking?

[mark_gober]

Gary,

I had this EXACT same problem on my 1995 windstar. It took me forever to figure out that the EGR valve/DPFE sensor weren't the problem. I purchased a new tube and despite my fears, it actually came out rather easily. (easy from the standpoint of not being rusted permanently together). If my memory serves me right, the EGR on riser tube connects on the back side of the engine which makes it cumbersome to get to.

Do yourself a favor and soak that sucker good in PB blaster or WD40. I'd let it soak for a day or two. You can't use too much of this. Make sure you have THE RIGHT sized wrench and it should come off. If you mangle it up good, worse comes to worse, a pipe wrench is a sure fire way to get it unstuck, but they are large and may be difficult to wedge in there.

Good luck, I hope it goes smoothly.

Mark