Engine Early Explorer Lower EGR Coolant Fitting

sav22rem22

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Feb 6, 2020
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So I recently bought an early explorer upper and lower with the act already drilled and tapped however the egr coolant fitting hasn't been drilled and tapped. Does anyone know what thread I would need to tap it to? And would I be able to swap the fitting from my stock lower over? Sorry for making another explorer intake thread I just couldn't really find this specific bit of info.
 
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Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
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Yes, 3/8NPT. Stock intake fitting will swap over

096AE31A-1040-4419-A91F-A318C3941611.jpeg
 

Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
36,405
12,310
224
Massachusetts
Correct, also 3/8 npt.

see this thread


 

sav22rem22

Active Member
Feb 6, 2020
218
28
38
19
North Carolina
Correct, also 3/8 npt.

see this thread


Okay thanks. When tapping for 3/8 npt on the lower for the egr coolant port do you recommend using a 9/16 bit? I know the correct is 37/64ths but i know thats going to be a real pain to find. Also when drilling it out should i start with a smaller bit first and work my way up?
 

Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
36,405
12,310
224
Massachusetts
Yes, but it will be tight. You’ll want a sharp tap and use plenty of cutting fluid and clear the tap often.

the 37/64 tap would be more ideal, and you can get those at Amazon or Home Depot if you order online and ship to store.

if you have any concern with cracking the intake, go with 37/64
 

sav22rem22

Active Member
Feb 6, 2020
218
28
38
19
North Carolina
Yes, but it will be tight. You’ll want a sharp tap and use plenty of cutting fluid and clear the tap often.

the 37/64 tap would be more ideal, and you can get those at Amazon or Home Depot if you order online and ship to store.

if you have any concern with cracking the intake, go with 37/64
Alright I’ll go with a 37/64. I’ve watched a video on the fitting and it seems much much thinner than I originally thought so it shouldn’t be bad if I take my time and do it right. Thanks for the help
 

Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
36,405
12,310
224
Massachusetts
Just pay close attention to the photos in the link I provided earlier. You can see that the pipe fitting fits rather close to the intake plenum. As such I would recommend favoring a slight angle away from the plenum to allow the fitting to thread in nicely. Not much, maybe 1-2 degrees away. You can see by the pics what I mean