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  #1  
Old 08-03-2021, 11:19 AM
kiallowski kiallowski is offline
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Default 2002 Mazda B4000 EGR Tube disconnected from Exhaust Manifold - Help

Hello folks,

I just bought my first used truck which is a Mazda B4000 (basically a Ford Ranger), V6, 4.0L, 4x4 (which I'm loving so far, minus all of the money I had to dump into it... but that's the way she goes I guess...). It has about 129,000 miles on it. I recently brought it to the Muffler shop, where they put in brand new Catalytic Converters (which I bought on Rock Auto) and a new Muffler system, which they provided. Not a cheap fix, but It has been worth it and is not as loud as it was when I bought it anymore. They said that everything else on the truck is in good shape, minus the EGR Tube/Valve/Manifold. I knew I was going to have to put money into it. You kind of have to with old trucks.

Anyway, they showed me that the EGR Tube was disconnected from the Exhaust Manifold and they gave me all the parts numbers for the EGR Tube, EGR Valve and Exhaust Manifold. I found all of the parts on Rock Auto for a reasonable price, and I'm still shopping around.

Lastly, the mechanics said that I could buy just the EGR Tube and they could try to get it back onto the original Exhaust Manifold, but didn't guarantee that that would fix the problem with the disconnected EGR Tube because the tube and valve is worn out (because it is the original).

Now, I'm debating on whether I should just start by buying the EGR Tube and see what they can do like they said. Or would it just make sense in the long run to buy all three of the required new parts (EGR Tube, EGR Valve and the Exhaust Manifold) and have them install it?

Do you think I will be able to get away with just a new EGR Tube and Valve attached to the original Exhaust Manifold? I'm leaning more towards buying all three of the parts, because the existing parts are all original and corroded, but I want to see other opinions. The parts aren't that expensive too which is good. Only bad thing is paying for labor.

Also, will a new EGR Tube, EGR Valve and Exhaust Manifold make the truck sound quieter? What will it help with besides emissions and combustion?

Will I be able to drive long and short distances with it broken?

Thank you for any input!
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  #2  
Old 08-03-2021, 01:26 PM
DailyBeater99 DailyBeater99 is offline
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Default Re: 2002 Mazda B4000 EGR Tube disconnected from Exhaust Manifold - Help

I would do anything to avoid having to replace that exhaust manifold, but I also don't think that you'll ever get a new EGR tube into your old manifold either. Maybe just have someone take a new EGR tube and try and weld it around the base of the old one? I tried taking my exhaust manifolds off and every. single. bolt. broke. Welding nuts to the broken studs just resulted in shorter studs when I tried to take the nut off, and drilling it after the nice heating and cooling process the welder provided was almost impossible. I cursed the truck so many times I lost track. I ended up replacing the whole motor, as I could see I was facing an uphill battle with mine. (There was something else wrong with the motor that I was attempting to rebuild, but after just the exhaust manifold fiasco, which was resulting in me having to drill and tap threads in the cylinder heads, I determined there was no sense in rebuilding this 20 y/o rusty POS lol).

It'll run fine with it leaking slightly, but if it's leaking a lot, then you run the risk of running a little lean (which is never good). Not sure how much the computer will adjust the fuel trims based off of the O2 sensor readings or not. Other than that, that leaky tube not leaking anymore will surely quiet down the engine bay, and fumes trickling into the cab and such.

If it were my truck, and I wasn't worried about emissions or anything (which I'm not), I'd just cut that EGR tube off flush and weld it closed and forget about it.
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Old 08-03-2021, 02:17 PM
kiallowski kiallowski is offline
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Default Re: 2002 Mazda B4000 EGR Tube disconnected from Exhaust Manifold - Help

I live in New York State and I may need it to pass emissions down the road. Also there is a reliable muffler shop that did my CC's and Muffler that also specializes in working on broken and old exhaust manifolds. They mentioned how they might be able to weld on a new EGR Tube to the original Exhaust Manifold, but also, they might be able to replace the EGR System it if I buy parts (EGR Tube, Valve and Manifold). I don't believe their is a hole in the Manifold and I have Zero Leaks from that area. The Tube is just disconnected form the Exhaust Manifold.


Would it be good just to buy the EGR Tube and see what they can do in attempting to attach it, instead of buying all three parts and having to return them. The mechanics gave me the proper part numbers which aren't that expensive.


Wouldn't it be good to have a completely brand new Exhaust Manifold and EGR System in the long run? Especially because I'm in New York State. Mine is the original one.



This is what they say on their website:

"Exhaust Manifolds:

Exhaust Manifold replacement is a large part of our business. Whether your manifold is cracked, corroded, or the bolts that hold the manifold to the head have broken causing that annoying ticking sound we can fix these issues. We have the ability to remove broken bolts from the head on the engine without major engine work. This is a process we have mastered over the years. If parts are unavailable for your car or truck. We repair most manifolds by either welding them or having the warped mating surface machined to be perfectly flat again and reused."

It sounds like they can do the work...


Thanks for your input!
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Old 08-03-2021, 02:23 PM
DailyBeater99 DailyBeater99 is offline
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Default Re: 2002 Mazda B4000 EGR Tube disconnected from Exhaust Manifold - Help

Sounds like they are the perfect shop for that kind of work then. Worth every penny they charge! I've never personally had issues with exhaust manifolds other than getting them off. If they can replace just the EGR tube then have them do that. No sense in replacing more parts than necessary on these trucks IMO. What's that shops name? I might have to ask them what tricks they know that I need to know lol


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Old 08-10-2021, 12:06 PM
kiallowski kiallowski is offline
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Default Re: 2002 Mazda B4000 EGR Tube disconnected from Exhaust Manifold - Help

I have another concern! Will it be fairly ďeasyĒ for the mechanics to take off the old exhaust manifold and install the new one without having to disconnect other parts around the EGR System? Like the engine, etc. Iíve read, at least for other cars and trucks, that mechanics have to drop the engine and stuff to install a new Exhaust Manifold. I was looking from the top of the engine and underneath where the EM is connected to the Catalytic Converter, and saw where they could could work through some openings. Iím sure with extra long tools, they could be able to maneuver around and install the new manifold after a few hours hopefully. Any thoughts?

Also, will these nuts and studs fit the Exhaust Manifold I bought?

https://www.rockauto.com/en/moreinfo...=15114&jsn=529
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Old 08-10-2021, 12:13 PM
DailyBeater99 DailyBeater99 is offline
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Default Re: 2002 Mazda B4000 EGR Tube disconnected from Exhaust Manifold - Help

Quote:
Originally Posted by kiallowski View Post
I have another concern! Will it be fairly ďeasyĒ for the mechanics to take off the old exhaust manifold and install the new one without having to disconnect other parts around the EGR System? Like the engine, etc. Iíve read, at least for other cars and trucks, that mechanics have to drop the engine and stuff to install a new Exhaust Manifold. I was looking from the top of the engine and underneath where the EM is connected to the Catalytic Converter, and saw where they could could work through some openings. Iím sure with extra long tools, they could be able to maneuver around and install the new manifold after a few hours hopefully. Any thoughts?

Also, will these nuts and studs fit the Exhaust Manifold I bought?

https://www.rockauto.com/en/moreinfo...=15114&jsn=529

It's possible to replace the manifolds in the truck. Only difficulty is when the bolts break and they have to use the torch to heat up the manifold to get them out... It would certainly be easier if the motor was out, but not necessary by any means.

And not sure about those bolts... Rockauto didn't have anything for my 99. I have 6 on each manifold, yet that link you included has 10. Not sure if the bolt size and thread pitch changed or not. Haven't even gotten to the point of measuring mine yet. Was just going to run to a local bolt company when I was ready to put new manifolds on.


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