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302 Upper Intake Removal


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#1 snowman74

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Posted 04 May 2007 - 04:29 PM

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Hi y'all...
Finally taking the damn upper intake off to repair/replace fuel injector wires...running into a couple of problems...

First, I removed what I think is the EGR valve on the passenger side...bolted onto the upper manifold, right by the throttle body. Is that what it is? Anyway, the tube going into the bottom of the valve is FULL of some kind of black crap...I assume oil is getting in there some way, but don't know. Any ideas on what I need to do to fix this/prevent further build-up?

Second, I've removed 5 bolts on the outer perimeter of the upper intake manifold. Two on front, two on back, one on driver side. It still won't come loose. I ran my hand under the manifold on the passenger side, it appears to have at least one bolt under there...but for the life of me, I can't figure out what the fitting is (allen, torx, etc.). I also can't figure out how to remove it.

HELP GREATLY APPRECIATED!!!

Snowman74 :)>-
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#2 snowman74

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Posted 04 May 2007 - 05:03 PM

Okay, I think I figured part of it out... it looks like a T-40 Torx head on that bolt under the upper plenum. There's an opening in the top of the plenum to get to it...but a torx socket WILL NOT FIT under there...even if you run the socket under the manifold with one hand and try to get at it from the top, the socket is too big and hits the side-wall of the plenum. So, it looks like a long, straight torx bit is in order...where can I find one of those? Where's my Tylenol?
Snowman74 :)>-
Snowman74


1987 Ford Bronco XLT (full size)
302 EFI (speed density)
4 WD, Manual Lockers, 4 Speed Borg-Warner T18 manual tranny
Headers, Flowmasters, CAT-Less Exhaust
Bridgestone Dueler A/T Revos 235/75R15

#3 miesk5

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Posted 05 May 2007 - 09:35 AM

Okay, I think I figured part of it out... it looks like a T-40 Torx head on that bolt under the upper plenum. There's an opening in the top of the plenum to get to it...but a torx socket WILL NOT FIT under there...even if you run the socket under the manifold with one hand and try to get at it from the top, the socket is too big and hits the side-wall of the plenum. So, it looks like a long, straight torx bit is in order...where can I find one of those? Where's my Tylenol?
Snowman74 :)>-


yo!

Intake Manifold Removal Tip & Tool in an 86 302 Source: by Sixlitre

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#4 Jerry D

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Posted 05 May 2007 - 03:23 PM

It is a 5mm hex head. Trust me it is not easy to get to. It needs to be on a 1/4" drive with an 8" extension. or a an equel sized flathead screwdriver. It will make you cuss and it will make you upset. Just try not to throw it to far. Check the inside and you might have to clean it out really well if you are goin to reuse it again.
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#5 snowman74

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Posted 05 May 2007 - 04:26 PM

Thanks guys...

It is a T-40 TORX head. The socket WILL fit in there only if you run it under by hand, get it at the PRECISE angle, and run a socket extension through the service hole on the upper plenum. I got it off there finally!!!

Now, the thing I think is the EGR valve and tube. The tube going from the valve to the intake manifold is on the manifold with about a one inch flare nut. I want to remove this to clean it out. Problem is, a wrench is not doing the trick...not the right angle to turn. Any ideas?

Thanks again!
Snowman74 :)>-
Snowman74


1987 Ford Bronco XLT (full size)
302 EFI (speed density)
4 WD, Manual Lockers, 4 Speed Borg-Warner T18 manual tranny
Headers, Flowmasters, CAT-Less Exhaust
Bridgestone Dueler A/T Revos 235/75R15

#6 Roadkill

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Posted 05 May 2007 - 07:29 PM

Now, the thing I think is the EGR valve and tube. The tube going from the valve to the intake manifold is on the manifold with about a one inch flare nut. I want to remove this to clean it out. Problem is, a wrench is not doing the trick...not the right angle to turn. Any ideas?Snowman74 :)>-

Maybe a "crow's foot" wrench?
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#7 snowman74

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Posted 05 May 2007 - 08:35 PM

Maybe a "crow's foot" wrench?



That's precisely why we all come to this site...to get an idea we probably would have taken two months to come up with ourselves. Thanks Roadkill...I will give that a try...just hope I have a crow's foot large enough.
Snowman74 :)>-
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1987 Ford Bronco XLT (full size)
302 EFI (speed density)
4 WD, Manual Lockers, 4 Speed Borg-Warner T18 manual tranny
Headers, Flowmasters, CAT-Less Exhaust
Bridgestone Dueler A/T Revos 235/75R15

#8 Roadkill

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Posted 05 May 2007 - 11:34 PM

You can get crow's foot wrenches to fit on the end of 1/2" extension at any place that sell good tools, but the larger ones can be a bit pricey for a tool you will only use once. If you're like me, you probably have lots of wrench sets laying around. If you have more than one that fits the nut, you can heat one up and custome bend it to fit your needs. I have done that in the past and it works pretty good. Down side is that the bent wrench won't be much good for other uses any more.

Edited by Roadkill, 05 May 2007 - 11:35 PM.

96 Bronco XLT
351W, E4OD, BW1356, Warn Premium Hubs
6" Suspension Lift, Super Runner Extended Radius Arms
35x12.50 ProComp MT's on 15" Rock Crawler Wheels
4.56 gears, ARB lockers front and rear
K&N FIPK, Flowmaster 40 Dual Exhaust
STC Soft-top (in the summer-time)
A work in progress...


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--- John Wayne

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#9 Yardape

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Posted 06 May 2007 - 11:12 AM

My tube was broken, I just used the box end of a wrench and it came off quite easily.
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#10 firelt90bronco

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Posted 10 May 2007 - 06:35 PM

I use an adjustable wrench to get the EGR pipe off. While the EGR is out, take some carb clean and clean all the carbon out of it. Use a screwdriver to push the bottom plunger down and spray all the crap out.
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#11 snowman74

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Posted 13 May 2007 - 12:40 AM

Finally got the tube removed...cleaned it in parts washer...put tube back on, put intake plenum back on. Darn near done with this deal...thanks to all for the help.
Snowman74 :)>-

Edited by snowman74, 13 May 2007 - 08:11 AM.

Snowman74


1987 Ford Bronco XLT (full size)
302 EFI (speed density)
4 WD, Manual Lockers, 4 Speed Borg-Warner T18 manual tranny
Headers, Flowmasters, CAT-Less Exhaust
Bridgestone Dueler A/T Revos 235/75R15



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