Explorer 5.0/GT-40, Plugging EGR Questions?

[needabronco]

What are you guys/gals doing to plug the EGR hole in your GT-40 intake manifolds? I tried to use a freeze plug but the hole is a hair too big, I also have a threaded plug that would fit, but I can't seem to find a big enough tap thats NPT. I want it plugged so I can simply bolt the throttle body to the intake manifold, can this be done? What have you guys done? Thanks. Casey

 

[spatacuulous]

Casey, When I eliminated my EGR, the only hole I had to plug was on the passenger side Exhaust manifold, not the intake manifold. I have a 1998 Explorer 5.0 motor in there. I just used the original nut that was in there and welded it closed. I have pics if you need em.

 

[needabronco]

I have a 96' Explorer setup with the internal EGR. Theres a rectangular hole in the head and bottom of the lower intake manifold that turns into approximately 19mm ish round hole where the upper and lower intake manifolds meet. If I could find a tap, I'll tap the upper and lower intakes and plug them both. Otherwise I suppose I'll just have to run the elbow with the EGR valve.

 

[broncnaz]

Some intake gasket sets(felpro p/n 1250) include a block off for the heat riser from the head to the manifold. You might be able to use something like that. Although I'm not sure if the 1250s will fit a explorer motor

 

[needabronco]

I looked at the pic's of that gasket and I don't think they'll work. Here's a pic to help clarify what I'm asking. Does anyone happen to know where I can find a 3/4" NPT tap?

 

[broncnaz]

Right but if they will work at the manifold to head location you dont have to block off the port up there. Worst case you could make a tap take bolt or plug the same size you intend to use and cut 4 verticle slots in the sides you have just made a cheap tap should work real good on aluminum.

 

[FFMDX]

I took mine into a machine shop and had them drill, tap, plug and clean for about $30. I also covered the EGR holes in the heads as well as using a GT40 Phenolic spacer w/out the hole.

Sean

 

[Broncobowsher]

OK the '96 is basicly the same as the '86-'93 mustang just with a 90° EGR spacer instead of a straight one. Couldn't you just use one of the off the shelf EGR eliminator plates that covers the EGR holes?

Personally I would bolt on a mustang EGR spacer and hook the EGR up. There is the potential for ½ MPG or so improvment with it working.