6.7 Ford Diesel |Repair YOUR P0401!!!| The right way!!!

[Music] what's going on everybody welcome back to the channel today the beast we got here is a 14-2 fitty with 88,000 miles this old girl had the infamous p0 401 DTC and yes we're going to be removing this EGR cooler from a truck I know you guys have seen my intake removal video I believe it was when I was doing a turbo one in nineteen pretty much the same thing but nonetheless we're gonna get this tour off get this EGR cooler on the bench and I'm going to show you guys if you still have cooler and a 401 what you're gonna need to do to resolve that so alright let's get to it guys alright one of the first things we're gonna do here is drain a coolant of the primary and drain our coolant out of the secondary I showed you guys how to drain the secondary the primary isn't too bad to get to it's actually right there so let's get that coolant draining and yes we'll take the next step all right coming around here see we got the coolant draining and then over here for the secondary that's all you guys are doing is just pulling that line off and let it drain into the pan we're not going after the radiator drain like we do in the primary just that line bub drain it alright so we got this aftermarket air box we got some stuff we're gonna have to look around got our eight Millie clamp right here electrical connector and then our eighth note bolt holding this bad boy in so let's get this thing whittled out come on bud alright here we go sit down in there I'll come with more room we got so now we're gonna go we're gonna remove that air snorkel to the lower intake manifold eight mil clamp eight mil bolt work all this stuff out and you'll be able to wiggle air snorkel - okay guys so I'm gonna start here on the passenger side what I like to do right off the RIP is get this wiring harness out of my way all these coolant lines out on my way I want to start being able to visually see the EGR cooler and I'm gonna move over towards the intake manifold so first off I'm gonna disconnect the main PCM connector I don't know if you guys can tell here but right down the other side of this line little harness twang that we gotta get out of hole and then we'll be able to remove the connector like this so after that when you follow you know when you get this line let's get this one out of the way okay it has a twing right here get this out of the way so moving back to this harness if you follow this all the way down you can see not really not on camera there is a twang right here that I want to get out it sits on this little plastic thing the passenger side battery because I'm going for these two connectors right here these two bottom ones there's four total one two these ones are staying that gray one and the one underneath are the ones you're removing all right I got these two connectors up that I wanted and this PCM connector I've gone ahead and I've disconnected all the electrical connectors on the EGR cooler so right now we have this bundle of wires that's going to be totally out of our way one more step though on the front of the EGR cooler you'll see a trough a plastic trough and it's secured with two eight Milly's there's two of these bolts rip them off with the old milwaukee quarter don't lose them because you're reusing them now I can get this harness all the way down out and only I don't even want to look at just get it out of my way it's clouding my my repair area after that it's pretty much gonna be just getting these other lines off take this little guy off the EGR valve all these cool lines should be pretty much pretty much empty maybe tip them straight up to let any coolant drain down and all in that particular hose get this one off okay get this hose I'm gonna lay it all the way over here out of the way I'll deal with that in a little bit get this out of my way I want to see it so now that we're here you switch over a different socket gun and I'm going to actually remove this bracket moving right along across the top of the EGR cooler gonna be using these so don't get those don't get those nuts mixed up let go for these three big EGR cooler mounting bolts these are the primary Mona coolant passage so I'm just gonna go ahead and get these out of the way obviously reuse these don't lose them and have to take your vacuum off my house was just take it off here to get this out of your way this vacuum line just go ahead and route that down and out of the way take care to not break them sometimes they can be you know super brittle you know I'm gonna go ahead and rip this line out of my way cause it keeps flopping lastly what we're gonna do there some trim clips that fold a sound shield the side of the valve cover and it's actually clips into the EGR cooler body so we're going to get these clips off most of the time they break but the shield stays in place because it's held on by two clips three clips in the bottom once we get that off then there are two bolts one here and one a little further back you will need a setup like this maybe a little longer extension use hand tool and then what you break it loose you can use either your hands or you know a little power tool to get it the rest of the way so okay I got the two bolts out save them you're gonna reuse them now I'm gonna be moving right along I'm gonna go ahead and remove this intake manifold so let's get into that now shall we okay okay okay intake removal 101 hold on okay eight Milly's for the most part unless you got yourself a newer truck and they threw some different sizes at you back here in that corner but yeah let's call these eight Milly's out I'm more worried about this EGR pipe so we're going to now go for this electrical connector oops man it is Twain right here onto the intake sometimes sometimes I bust off a little bit get that out of there I don't want to see it let's get that boy back there get him hide and got harness tab locator on the back of the intake go ahead and pop that out once we get these lines off there'll be another one for the waste a waste gate to vacuum line I should say see if we can get this quick disconnect give it a spin hit these tabs just like that pop it off I go down underneath that AC line so it's out of my way and then I can come back with my quarter drive ratchet setup [Music] continuing okay I both get into the end save it okay you guys can see I don't know if you can on the video but right here oh hey here right there is a clip that's holding this line to the trans dipstick tube I just want to go and take that plastic clip off this is what I'm talking about right here don't lose that and then the next is trying to get that oil dipstick tube bolt out of the intake manifold and I'm gonna come back here again with my quarter driz I've get that 8 milli got it I've got my magnet up here I'm just gonna keep it rolling okay that's your oil dipstick tube bolt only one goes and one spot can't can't really mix them up and I suppose you could so what I dunno tikis these buggers out of my way this is how they sit I go like this okay and then I just I'm just pushing it right on top of the CCB box see how much more out-of-the-way they got come back here with my quarter Drabek in they get this one yep get these four okay that rubber hoses in the way and get this get this out of here okay I was just sitting on top of my Pole [Music] kind of a pain to get through we can't really see it and that should be completely loose right here okay your intake should look like that then intake gotta be careful here sometimes I zip tie it to this ground strap but other times it just stays there we're just gonna try to keep leaving it so now the intake has got to come like this it's gonna be pretty close over here what I take is take this tube see how much more room I get here that allows me you see what just happened I just came right up let's watch that again okay and takes down where it sits I'm pushing out these tubes this kak tube out of the way look now my bolt drop down and won't come out the second time see just like that and then the intake moves just like that guys okay so now that you got it off either cover your intake ports with these trittye looking covers or get you some freaking rags six it will start up Oh No that sucker is allowing let's go ahead and get this little pipe off here get this can you walk us out of our way a little we'll clip right here on the lower intake manifold to remove what I'm just gonna go ahead and rip these guys out you know but risk with this job unfortunately is or are these EGR [Music] manifold if you guys remember my 2020 video where I showed you how real plus those bolts were looking they were ten mil bolts instead of these little little eight million guys okay I'm just gonna leave this guy just sitting right here on top of the belt just sitting right there we need to remove the electrical connector next I'm going to be going for this connection down here this exhaust back pressure connector the connector rubber isolator and she'll stayed in the sensor so just be careful of either dropping that or you know making sure to reuse that over here on the back of the EGR cooler I think I can show you there is stud right there there is a little little harness twing that needs to be removed and also another one down on the backside of the cooler visualize with me this is the cooler I'm looking from the back to the front and this is the twang that I just took on like the cooler would be sitting in here I just took this twang on the other harness twang is right here so you're gonna need to get your panel popper and kind of go in something like this like I said you get the twing off the stud here so I'm gonna go ahead and do that and get this all removed 10mil not holding the EBP bracket don't take the nut off just take it off back it off just a little bit because it has a bracket that swings down over the stud and then you tighten the nut and that pinches the bracket to the backside of the cooler so don't remove the nut just leave it leave it on the cooler and the exhaust back pressure flare nut is sixteen million okay i've removed that twang over there I've removed this for your guys's sake I hope it was this loose on the tube as it was for mine sometimes I see these really locked up and I got to work it back and forth and Lube it up and back and forth and it's just a pain just to get this thing off but it worked out worked out in our favor today all right we have two bolts left here on the cooler go ahead switch sockets I'm saving the worst for the last I feel like jumping back up there I'm gonna use my magnet here pull this one out this one out this coolant line that we moved over here by the AC line I'm gonna take and put my up here about the turbo right above the turbo a pipe on the passenger side manifold that brings us to our final piece oh lordy Lordy I hope this goes well I'm going for this pipe right now EGR valve before because one of the different chassis for pickups is our EGR valve is test this one is aluminum so I don't have too many issues with these bolts just a couple of time they broke but here they are look decent and getting a little bit of things ID right now trying not to this is the bad bad lad right here got a cut time to change gloves okay here we go real time they're either gonna bust or they're coming out I've done this two ways I'm gonna put a link in the description of my number one searched YouTube video for EGR bolts breaking on six seven and I kind of go through the procedure on how to fix that I'm hoping I'm not gonna have to do that today but I'd use this got a fresh 8 milli on here kind of a hand impact driver I've also used a long 3/8 extension same bit I'm sorry same socket and then smacked it with the old hammer do so I'm gonna go ahead and start with this right now I apologize about the loudness because I'm about to get Wicky wild just busted the socket guys oh come on okay no I switched over to a used impact socket oh man come on baby that thing is in there man let's try this one dude hey oh okay you guys man this was this is becoming quite uh quite a pain I tried using my driver with my air hammer that still didn't work I just put this concoction on it and it just broke free and I find that highly unusual I don't know if this is too good to be true or what but I want you guys to loosen it here with me it's pretty pretty weird if you ask me how to tighten it then get some lube and I'm gonna do this process back and forth hopefully it does not have a poor outcome get that down in there okay I can feel the lube get on that already come on puppy huh come on puppy you spray some more before I go too far right here we go going back off eels Hills alright getting here to the top I want to say anything bad like I see the gasket flopping around okay got it by hand all right let's see what our non ferrous Bolt looks like oh that was that was stuck in there man we got one more I sure as hell hope one's better than one's better than both having them break okay I haven't touched this one at all since I was air handling so you guys can see the gasket jiggle around down there there's first torque can I turn this just a smidge more here we go okay it already seems loose maybe I was turning it okay let's do the same same ordeal DTR diesel Tech run I hope you're watching down on me alright PA man I hope your family's doing well I think about you every time I use my WD and some of my other essential tools that I got just because you were using them tried email and his family and see how they were all doing but I haven't had a response back yet but understandable life's moving by that's the peace buddy and even rusty bun - rusty bun Senior Master Tech rusty bun make sure to check out his channel - guys he's got a lot of good 6oh content head gasket removals in chassis oh good - good technicians out there okay you guys I think we were successful oh my good no movie magic on this one straight up takin taking some time minimize the risk there's a risk with doing an EGR cooler and it's having these bolts break off in your exhaust manifold focus there you go came out alright guys oh my goodness alright so now that we got this malarkey out of the way down my gasket oh I'm Oliver get sceeto okay there's the cooler she's heavy she needs to be taken off level if you tip it you're gonna get douche with coolant I'm not for warning you but I would probably really do where your air filter housing is maybe put a drain pan in there so that you can just go whoop right into the drain pan and then take the drain pan with the EGR cooler and lift it off the truck and onto your bench next shot you gonna see this cooler on the bench what I usually do is take the cooler and tilt it back and forth and then flip it upside down and do the same thing to get coolant coming out of those two ports and then the two ports underneath just so that you're not making a mess here on your bench so let's get it set up reel the cart over here and yeah all right I like to put it right on the edge of the bench like that what I'm gonna do as you guys can see that there are two pieces here I have this piece here and this piece here we do not want to separate the EGR valve from our EGR cooler bypass we want to take the EGR cooler bypass off of the EGR cooler housing so do not touch any of these bolts only the perimeter a lot you must remove this bolt right here because this bolt is like this long so we're gonna head become a setup that I use is just this right here you can throw the bolts away because we are not reusing them Oh okay sometimes EGR valve bypass wants to separate immediately from the cooler but sometimes the dowels that it sits on can be a little rusted it's going to get a flat blade skinny try to go between the gaskets I don't want to mess up the metal of this I don't care about the cooler because I'm replacing the part that I'm trying against I'm just working this off the two dollars that are located at the bottom of holden sometimes of dolls stay gotten one ah now there we can see how the dowel stayed on that one we're just gonna leave it check it out look how blew out that cooler is o'clock notice inlet/outlet alright so we're gonna do that the cooler around come here to the backside called that ten mill nut I was telling you guys about boss back pressure tube and here's that other stud remember I was showing you guys visually where that other locating tab this big bolts back here are thirteen this only goes on one way although it looks the same the gasket and this only go on this way okay so the cooler is ready to be removed you're not using any of these gaskets alright get it in the vise I want the front the heat exchanger to come out that way what I've been doing is using two hammers a sickle and Hammer it and I'm alternate between those ports on the back and I'm just going to drive that heat exchanger out with my bfh usually doesn't fall out like that but when you bust it loose uh yeah it falls out somewhat like that here it is check it out now I know a lot of why would you even put this thing back on because I got to got to play by the rules but what I like to do is is clean this in a vat of water just go and douche it all out I got two O rings I got to take out here I want to clean up this surface with the cookies clean up that surface and then this surface and then we're gonna do the same for our EGR valve bypass I got the EGR cooler all cleaned douche it out with water while the surfaces are nice and clean and taking care along with this and the EGR valve and bypass everything's almost a clean in order to do the cooler you're going to need the gasket kit 11 through 16 are all going to be the same piece de resistance EGR cooler box that's gonna have the new heat exchanger starting off let's flip the cooler over big ovens pretty much just gonna work them down into the groove that's sitting in the cooler backs these are both gonna have to be I like using this stuff just putting a little bit so if you guys can see everybody's played with Legos I sure hope they could figure this out see what that looks like does that look like that right there no it doesn't does this one look like that yeah it does so we're gonna be putting this gasket on here for a missing dowel here trying to keep everything nice and straight so that when we put that bypass back on that dowel will line up brand-new heat exchanger check it out you guys can put the 17 and up core in it gaskets and everything that stay the same cooler guts are way bigger got bigger straws and let me see if I have one over here all right I found it guys this isn't 11 the dude after or before he took this off he wanted 17 and up EGR cooler see those holes and then see these holes this has got about 50,000 on it you can see it's barely barely even clogged but I just want to show you guys this as an alternative if you guys don't want to use what came out you guys can put the newer guts in we're gonna put some lube right around edge now how Plus this in my show you guys trying to keep that that gasket lined up I'm going to set this on the floor and I'm gonna put my body weight I'm just gonna I'm pushing down like this right against the floor and I'm actually gonna do it until my feet lift right up off the ground and boom then it goes in you don't need to hammer it in him I just put it on the floor and push it went right in that can actually take these two tabs right here and I can slide that gasket around next gasket though to make sure we put that on it actually has some wording on it that tells you that that is the bypass side the gasket we put on before said cooler side and sometimes when I go to tip it cooler will drip out right there see do that before I do that all over that new gasket just make sure I get all my coolin out all the bolts are in obviously there's a torque spec but I'm not going to torque them I've done this enough to where I know the power of my tool my gun that I'm going to use and just watching the bulb turn [Music] now I'm gonna go back around it once more [Music] I do it one more time now that that's done I like to put the bottom on last so that I can use the EGR cooler kind of like on a stand anyway I'm not facing the front of it like I was that looks good go on like this or is it gonna go on like this I see the part number I'm gonna say it goes on like this and again I'm just running these boys down that was my 3/8 gun and I was just running them all the way down I'm not gonna go over there again because I'm gonna snap the bulb up I just went until the bolt stop no big deal 10 Mele don't forget to put your nut back on over here how it sits the cooler is ready to be reinstalled back onto the vehicle but and that's one big button before you start you guys need to put these two o-rings in the valve cover on the engine since you're there you might as well go ahead and grind that manifold just clean up that gasket surface and get these installed and then you're ready for installation guys ok we're back over to the truck got my new gaskets installed I clean the manifold and I put some ARP head stud lubricant down in them holes on them bolts when you guys set the cooler back down I mean it is kind of heavy just not pretend just take precaution not drop the fuel on any of these injector returns that guy who actually took that cooler off that I showed you with the bigger 17 up EGR cooler guts he obviously didn't know the weight of the cooler prior to removing and I'm assuming when he bolted it dropped and broke the rejector injector return off of injecting number four so just be careful and float in the back and the front it sits down on dowels what I'd like to do first is get these big boys seated down we're gonna have to take one off there was a bracket if you guys remember that one there I'm gonna start with the middle one you guys saw it go right down smash those o-rings that's nice and tight I like it I like it now it's important to me that I put everything back in the order that it was removed a couple things I want to point out here I have had wiring problems right here where these fingers right here on this heat shield tap make contact with these wires for the exhaust back pressure sensor when you guys go ahead and slide that back down around orientate the fingers in a fashion that does not hit those wires so that you guys don't get a chafing the other thing that I like to do is the heat shield can for the turbo it's just flopping around too much like this like this just kind of kind of doing its little thing I don't really like that I like having it like this it's not moving it's not backing off it's not in the way of the intake it's straight and conducive and how I like to do work so those are just a couple of pointers that I want you guys to make sure to pay attention when you're installing it back on and additionally once you're done with that ege BP get your coolant hose and snake a coolant hose back over to where you had it and install these two bolts in here like this these bolts are actually gonna hold our gas what we'll do we're going to follow the plate down with the socket just like this and float it right above the hole we're gonna start that one by hand start this one by hand my straight socket so that we can run these down just the world war yeah they're definitely started that one kind of scared me for a second but definitely started right down here a little more that's gonna go ahead with our second Gasquet I like to install it like this so I have that flat on the top bolt so here just worked it you can find the hole in the gasket okay once that is on we're gonna come back over here to our EGR bolt that we put in I can take this out coolers down removing that bolt isn't gonna okay so if you guys remember this we need everything nice and loose yet throw that down get these guys in here that plate to bracket now I am gonna draw a pipe in first and then I'm gonna do the bracket excuse me give a snug snug you know somebody out there's probably saying snugs get that one plainly this one with the longest unnecessary back here we're gonna tighten these guys you shouldn't really see that pipe move at all that's pretty flush our lights going out okay we got light go ahead and put your vacuum line on to your bypass vacuum reservoir all what you're here go ahead and get your vacuum line and we're going to take that here it looks good so really right now what we're ready for is that upper intake manifold installation let's see if I can get that installed and show you guys process for doing them rich I got you I got you okay here comes remember we push down this pipe and try to go in the exact same way we came out but bolt came out move it over and we got I mean guys I barely even push down in there this thing set that down right down here just make sure your harness back here we do with that just out the way of just a wee bit there we go and the intake should jiggle around like that I just push all the bolts in there I kind of just follow themselves push them in the hold and take will still be nice and loose and then uh yeah bit just Milwaukee these boys right down it was a gasser couple more bolts to tighten I've had a lot of people trying to get a hold of me [Music] I've had people trying to get a hold of me you know via the comment section in YouTube and they're not very up-to-date I guess the best way to get a hold of me if anybody needs questions is email me go to the description or my about page and check out my email address and I'll make sure to get back to you there we go that's all good come back here and fish up our Matt sensor connector get us got a little twang here yep click this thing no problem you got some new got some new gaskets here pop these on these can be a pain in the butt to try to get on and line the bolt up but we always get it ok so just kind of get one one bolt started and just kind of twist a pipe and jiggle the gasket lined up with this you'll feel the bolt hole line up the gasket just can fight yeah that's good ok so this one should be right here persuasion let's see if we can see if we can draw it in pass the gasket again we're not torquing them [Music] don't forget your little clip that holds the harness then you guys can just see the corner of that um and then come over here and get your it's your quick disconnect line get these out of here also your coolant line that you moved out of the way earlier you're gonna go for all of this stuff now now it's just flopping around and nice and loose go ahead and start those small connectors and we need to put in our last corner bolt down there alright alright alright let's get these other coolant lines back on that guy down in here that guy that guy get this clamp and that's pretty much it we are going to need to put our big-ass banks air filter back in this thing back on here as big as it is it wasn't too bad too yeah now she's sitting like I wanted all right that's it you guys on how to do this EGR cooler on your 67 from start to finish there's one more thing I want to show you but I'm gonna fill up both cooling systems first all right everyone I just got done filling up the coolant I filled up all the coolant then I took out of it don't worry that level will go down but I want to show you something as you start this thing up your truck may run rough time's shakes real bad don't be alarmed I don't know what it is if taking that off does that I don't know it doesn't do anything I've had it stall maybe a couple times which are replacements but enough to worry about so tell me what you guys think about the comment section below if anybody has had to in place there gr cool ducks there six seven powerstroke make sure too join the fam see it certainly left this a little bit right now how much you guys think I'll see you next Friday get some stickers after we go

Channel: PowerStroke Tech Talk w/ARod

Views: 47,857

Rating: 4.9511533 out of 5

Keywords: #pttwarodwantsa6.7, #6.7enginelight, #P0401, #fordtrucks, #6.7egrcooler, #forddieselegr, #egrrepair, #forddiesel, #powerstrokeegrcooler

Id: y06ZokJfroY

Length: 41min 5sec (2465 seconds)

Published: Fri Apr 24 2020