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2003 Ford Focus EGR Tube – nut size??

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  • #500847
    Daniel DominBlazerguy1983
    Participant

      I am attempting to replace the EGR Valve Tube on my 2003 Ford Focus with the 2.0L. I am giving trouble loosing the nut on the side that goes into the EGR valve right after where the two rubber vacuum hoses slide on. I don’t have a big enough wrench so I am trying to use a crescent wrench and I am starting to round off the nut. Does anyone have a suggestion on how I can crack it loose? There isn’t very much room to work either. Also does anyone know what size the nut is on the tube? I read somewhere it is 32mm but I want to make sure before I go and buy a wrench. I attached a picture of the part. I found a Dorman replacement part on eBay for it. I guess this is a common problem for how many places I found to buy it. Thanks in advance.

      DORMAN #: 598-112

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    • #500851
      619DioFan619DioFan
      Participant

        they get heat siezed pretty good. soak it with blasters and let it sit. not sure of the nut size , put cresent wrench on , adjust for tight fit , remove wrench and measure the opening to see what size you need. a pipe wrench will grab tighter then a cresent if you have the room.

        #501785
        Daniel DominBlazerguy1983
        Participant

          Thank you for your reply. Unfortunately I created a bigger issue. I thought for whatever crazy reason to use the side of a pickle fork and attempted to tap the bolt loose with a hammer. Well you can see where this is going. It came loose but, I also cracked the entire EGR valve off the intake and broke a chunk of the aluminum intake off. So, I am currently waiting for a replacement upper intake manifold from eBay to come in. Found one with lower millage and the EGR valve included for $55 and free shipping. I know what I did was stupid but, I still must say that I dislike Fords a lot. Every time I work on this Focus for my Mother something major likes this happens to me. It just seems that there was not very good engineering involved with these cars. I will post an update soon. Thanks again.

          #501848
          college mancollege man
          Moderator

            sorry to hear the trouble.when putting the egr tube back together
            put some anti seize on the threads of that nut.upon re install.

            #501978
            drthrift035drthrift035
            Participant

              You mentioned that Ford’s always give you problems. Here is what you can do in the future. Buy the Service Manual for the particular vehicle that you are working on. That way you can follow the manufacturer will let you know the right tools and procedures necessary when you have a task to do.

              #504826
              EricTheCarGuy 1EricTheCarGuy
              Keymaster

                That sucks. Sounds like you have a solution however. The right tool makes all the difference in a situation like that. Never use an adjustable wrench for that situation as you have found out. Use a quality wrench of the correct size. I say ‘quality’ because I’ve seen some brands of tools that just don’t fit snugly enough or are made of inferior metal and spread out when you put torque on them. If it were me I’d be breaking out the heat. Heat is your best friend in that situation. Here’s a video. Also, I’m going to post a video on the method I use when dealing with stuck fasteners.

                Good luck and keep us posted.

                #505116
                Daniel DominBlazerguy1983
                Participant

                  Update!
                  I wanted to give everyone an update on the Ford Focus. I did finally repair it. I had to order a new upper intake manifold on eBay. I got a great deal for a used one for $54.99 with free shipping and it included the EGR Valve. I ordered the new upper intake gaskets, throttle body gasket and egr gasket. Installed the new intake and when reinstalling the new EGR tube I put anti-seize on it so when it breaks again it will hopefully be easier to loosen the nut. Lesson learned use the right tool and don’t rush things.

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                  #505118
                  college mancollege man
                  Moderator

                    Ouch! that was a big bite out of the intake.
                    Glad to hear that it worked out.

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