As for sources for the union I recommended look to Grainger or Mcmaster carr as far as catalogs.

Parker and Hoke are a couple of options for manufacturers.

Joe

A tubing union was my first try. But the tube is a metric or odd size. I never could find a tubing union that fit <img src="/forums/images/graemlins/frown.gif" alt="" />

Probably too late to do you any good but don't be afraid to modify a tool to make a better tool for the job that needs to be done. You won't find a flare nut tool big enough for the egr nuts but you can make a perfectly servicable one by grinding a notch out of a twelve point box wrench, big enough that you can slip it past the tube. You'll have to shorten the wrench too to get the throw you need so just grind a notch across the handle where you want to break it (were talking a "halfway through" notch) set it on a concrete floor (notch down with a metal dowel propped under the box end) and smack the backside of the notch with a hand sledge. It might take a couple of tries depending on the quality of the steel, but it should snap off. If not, just grind some more or use a cutting wheel if one is available.

Making one from a Craftsman or Huskey wrench is probably cheaper,
but there ARE indeed flare nut wrenches big enough for the EGR pipe.
I've got one.

My gasser '88 Troop had been disassembled by the previous owner - he had cut the EGR tube, basically right in the middle of the straight part coming off the manifold. He used a sleeve to join the ends together again.

This later failed, and I fixed it for free by using a Diet Pepsi can (Diet Coke may also work, or Pabst, give it a shot) cut and wrapped a few turns and held at each end by a hose clamp. Just a very slight 'tick' of an exhaust leak under load - probably could have been avoided by using muffler cement during assembly, but I am too cheap for that. That's what I'd do if I were you.

I also turned the can inside-out so it's not so obvious that I repair my car with garbage. It took on a nice golden color after getting hot.

Another method to get the head out is to not even worry about the EGR pipe and pull out the entire head/intake/exhaust assy as a unit.

It's heavier this way and you'll probably want to use an engine hoist, or a 2nd person. But it'll come right out.

You can reinstall it as an assy, too. There should be some old posts by Jerry Lemond here regarding using a couple of cut-off head bolts (or equivalent) at the back of the block, as alignment guides when you drop the head onto the block.

Once you have the head out of the vehicle, you may have better luck dealing with the EGR pipe.

HTH & G'luck.........ed

Thanks for the info guys. Hahaha, love the can trick Acy, that is great! I don't know if it will come to that but I will definitely keep it in mind! It seems like the can combined with plenty of putty and clamps might work allright!

I've tried a lot of different methods over the years to break loose the EGR fitting. A 3/4" Flare nut wrench fits close enough if I recall. You pretty much have to start with one though, or the damage to the nut will be prevent it from working after other wrenches fail. Here are some of the tricks I've tried with varying degrees of success:

I start by just spraying some PB blaster or other pentrating oil on it and giving it a try before I take the motor apart at all. If it doesn't go, I heat up the exhaust manifold and give it another go. I also tried heating the manifold up real hot either with a torch or by running the motor, and then putting ice cubes on the nut. The theory being hot manifold expands and cold nut contracts, it didn't work but the theory seems sound.

If I don't get it pretty quick, I give up try the other side briefly. On carb 2.3L motors it is very hard to reach, and on FI motors it is probably harder, so that usually doesn't work. Failing that, pull the head manifolds and all, then work on it out of the rig. Once you get one end free, you can slip a box end wrench over the free end nut and around the pipe to the stuck one. Apply heat, use a hammer and/or cheater bar on the wrench and it should let go.

I still have one that I had to cut off and never did get free. I had a spare manifold and pipe so I just swapped both parts. The other half dozen or so times I've fought this problem I eventually got the thing freed up.

ok, so over the weekend my egr pipe broke right at the bend where it comes out of the manifold. my question is, where does the other end of the pipe attach? and is it hard to get to? since my pipe is broken can i pull the exhaust manifold and get the nut out if its stuck? i'm also thinking of going the header route, so should i just not worry about the bolt till i pull the manifold?

sorry for all the questions, but i gotta know!

Before you permanently disable the EGR system, you might want to read the thread at

How Important Is The EGR?