Tough Repair Question - DFPE/EGR

[JIMBOBX4]

I was replacing the DFPE switch on my V6. This is an emission control part that (apparently) monitors the differential pressurre in the EGR system.
This part seems to fail regulary and often causes a CEL.

The part is simple to replace, two screws and two hoses to reconnect. Well, long story short the new part is of a slightly different shape and the the original hoses don't quite reach. As I tried to reconnect the hoses, I broke off the stainless steel elbow that the hose was attached to. This elbow comes right off what I will call the exhaust gase recirculation header, kind of like an exhaust manifold with the EGR sitting on top of it.

Against the advice of my local Advance Auto Parts Counter guy, I tried some high temp epoxy. It worked for about three months and then literally fell off (it also smelled bad as it heated up). Anyway, does anybody have a thought on how to fix this? Remember, this is a high temperature area and I think the stainless steel tube is of a specific calibrated size.

Should I just buy a new EGR header - any idea how difficult this would be to replace?

Any advice would be appreciated.

[shorod]

Any chance you could post a pic somewhere of the broken piece? Does the elbow that broke appear to be part of the pipe assembly that goes from the EGR valve to the exhaust manifold?

Also, what year is your Taurus and which engine does it have (12V, 24V DOHC, SHO)?

-Rod

[way2old]

There are 2 options. Purchase a new tube or remove the old one and find a shop that can weld it back on. Buying the tube would be the easiest and safest way to go.

[JIMBOBX4]

Originally Posted by shorod

Any chance you could post a pic somewhere of the broken piece? Does the elbow that broke appear to be part of the pipe assembly that goes from the EGR valve to the exhaust manifold?

Also, what year is your Taurus and which engine does it have (12V, 24V DOHC, SHO)?

-Rod

Thanks for the response. I have a 2000, 12V V6 engine. I believe the part is a known as an EGR Tube. Anyway, I have included two photos - the first shows the broken elbwo and the second shows the hole in the tube where the elbow use to be attached.






Way2old in a later post says I should just buy a new tube. It is hard to break down and buy a new part due to a stupid mistake, but I think that is what I will do. I guess I need to find a blown engine that doesn't need the tube anymore?? I went ahead and posted this in case it helps anyone else.

Thanks for the help.

[JIMBOBX4]

Originally Posted by way2old

There are 2 options. Purchase a new tube or remove the old one and find a shop that can weld it back on. Buying the tube would be the easiest and safest way to go.

Thanks for the advice. I guess I have no choice to buy another part. I guess what I should do is call the junkyards for a blown engine that I can take the tube off? I am afraid to think what the dealer would charge.

Any idea how difficult this would be to remove? It is located between the firewall and the engine and runs parallel to the dash.

Thanks again for the advice.

[way2old]

If the nuts are not rusted really badly, it is not too hard to do. Just take your time. I think the nuts are 1-1/16 inch