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1997 Mercury Sable tube to EGR valve broken

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Mar 2, 2017, 4:11 PM

Post #1 of 6 (574 views)
1997 Mercury Sable tube to EGR valve broken Sign In

By taken off the upper intake manifold to get to the rear spark plugs and to doing cylinder compression tests the tube from the exhaust manifold to the EGR valve broke off by accident between the two outlets to the EGR backpressure transducer.
I tried to disconnect the botton part of the broken tube from the manifold. However the nut is rusted in and it is not possible to take this part of the tube out for soldering.
Since the car is very old and I don't like to invest much before the car is scrapped, I like to know, whether the EGR components are very essential for running the car some more month without doing a proper repair. I could prepare a piece of copper tube and insert it into both ends of the the broken EGR tube and plug it together. Outside I would wrap arround some aluminum foil to seal the joint.
Would this work?
Your comments would be greatly appreciated!

kev2 profile image

Mar 2, 2017, 4:56 PM

Post #2 of 6 (566 views)
Re: 1997 Mercury Sable tube to EGR valve broken Sign In

at a professional auto parts store (napa) look at dorman parts - a special plastic hose designed for hi heat and EGR situations like this, looks works like heater hose.
There may be other brands available now.
good luck - let us know outcome

(This post was edited by kev2 on Mar 2, 2017, 5:07 PM)

Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Mar 2, 2017, 11:58 PM

Post #3 of 6 (549 views)
Re: 1997 Mercury Sable tube to EGR valve broken Sign In

I second that - NAPA can shine with finding kits to fix common breaks for things Dorman branded or other. Depending on break if hose will work there is a Silicone rubber hose that will tolerate these temps perhaps well over 450F. Aluminum BTW will melt with a common match - try it I just did!

Hard to know the spot and situation but would seek any possible way of use of copper, brass fittings instead of sealers or hose unless temporary will do as I think either would fail much faster than a metal fix known to tolerate those temps. Exhaust right at engines can reach glowing hot which is roughly 700F most metals are going to fail except copper and brass, iron, steels should?



Mar 4, 2017, 6:05 PM

Post #4 of 6 (509 views)
Re: 1997 Mercury Sable tube to EGR valve broken Sign In

Thank you all for the advice.
I don't think heat is a problem at the broken tube. About 1 inch below the cut a small tube branches out. There is one of the two small rubber hoses of the EGR backpressure transducer connected.
The other hose is connected after the orifice on a branch of the broken off tube.
Since the repair might be some problematic some knowledgable mechanic adviced me to run the car without the EGR system. The car should run well for the short time I need it. My older cars had no EGR systems.
Therefore I have to plug the broken off tube, the lower branch, the hole at the upper manifold where the EGR valve is connected and connect the two hoses of the EGR backpressure together. Hoping that the car will run after that reasonable.

Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Mar 4, 2017, 7:49 PM

Post #5 of 6 (507 views)
Re: 1997 Mercury Sable tube to EGR valve broken Sign In

I don't recommend disabling your EGR. That system serves a purpose. It reduces the combustion temperatures and running it without one can lead to engine damage.


We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.


Mar 8, 2017, 3:37 PM

Post #6 of 6 (481 views)
Re: 1997 Mercury Sable tube to EGR valve broken Sign In

I re-connected the EGR.
A short connection union (about 1/2 inch) was made which fits into both ends of the broken EGR tube.
The jount was sealed with WrapIt self fusing repair tape made by Versa Chem. The tape should be good for temperatures of 500F.
A hose clamp was installed on top of the sealed joint.
The EGR tube looks well after some test drive. The temperature of the tube is quite low. It can be touched by hand.

There is another problem with the engine. Some smoke will appear when it is hot. The reason seams to be a small oil leak around the black container below the EGR backpressure transducer and the EGR vacuum solenoid. A tube which connects into the upper manifold below the IAC valve is plugged into this container. A can't make out, what the container is for, since I have only a Haynes Repair Manual for the car at hand.
Can you help me?

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