I've replaced the plenum + intake gaskets on my Dakota this weekend and I've got almost everything back together except for the fraking EGR tube. The tube is tweaked just a little bit and it won't thread back into the intake, no amount of twisting, bending, hammering or colorful word play has got it into place and I spent 2 hours on it before walking away.

On the other end of the tube the bolts into the manifold are rusted all to crap and the heads have rounded off.

My choices so far seem to be

1. Try to cut the bolts off of the manifold side of the tube and attempt to drill them out.

2. Try to weld a larger nut on top of the manifold side and screw them out. Not sure if this will work since the condition of the bolts is questionable.

3. Remove the intake again, try to line up the intake side and start it before reinstalling the manifold. I don't really want to do this as I'm fairly sure I'll end up having to buy all new gaskets again.

4. Cut the tube and attempt to find a patch to put it back together which I'm not sure is possible.

5. Say screw the EGR cut the tube, plug the manifold and intake and go on my way.

Looking for any advice as to make it possible to get the tube hooked back up or as to which (if any) of the options I've got would work or if somebody smarter than me has a better idea.

TIA

 

Try using some heat. Heat will help bend it. Or just get a new tube. I believe I paid less than $20 for one. I cracked mine while trying to bend it into place.

 

Well I finally got it tonight, not sure if it was the heat from the welder or the hammering the socket on but the manifold side unbolted which allowed me to reconnect it at the intake.