Has anyone ever rounded the nuts while trying to install the egr blocker and how did you remove them? I tried every known penetrant know to me and still couldn't budge them!

If they are staring to get rounded your going to have to try to find a 6 point box end wrench. It took allot to get mine off too, those f***ers are tight.

I just loosened mine today. The only way I could do it was with a ratcheting box end 12mm wrench. Nice thing was that after I got it broke loose, I could unscrew it with my fingers.

I got the blocker in, but now it's screamin like a banshee so it's either not seated good or I need a gasket. Here we go again...........

The nuts break loose better when the engine is hot. IMO

i have one of mine rounded off, i managed to fit a 3/8ths ratchet with a craftsman rounded nut socket puller in there! it was tight as hell, but it worked! i however did not replace the nut like i should have! so the stupid rounded one is back on!

Craftsmen makes a tool that should be able to get them off so you can replace with them a better grade nut that will not strip next time.

Craftsmen makes a tool that should be able to get them off so you can replace with them a better grade nut that will not strip next time.
Sounds like a good father day gift! Definetly gonna try this weekend!

I got the blocker in, but now it's screamin like a banshee so it's either not seated good or I need a gasket. Here we go again...........

DoH! That sucks man. I tried using my blocker from my previous truck (lbz) into the lmm...ended up with the same noise as yourself and found out the one for a lmm is much larger.

DoH! That sucks man. I tried using my blocker from my previous truck (lbz) into the lmm...ended up with the same noise as yourself and found out the one for a lmm is much larger.
I fixed it. The plate was not pushed down far enough and exhaust was pushing out around the bottom.

Ok here is an update, bought the Craftsman rounded nut remover and have tried a #6 and a #5 and no luck, just sore hands and forearms. I am just about ready to say smurf it and roll on. Any suggestions?

At this point there is no saving the nuts or studs. Get a new set of studs and nuts. Gonna have to cut them off with either a cutting wheel on a die grinder or carefully with a torch.

Ok is there anyway to remove the studs with the nuts? THIS IS B.S. and I would love to drop kick the idiot that overtightened them!

best way (most time consuming....and pain in the balls...) remove the intake. then take the pass side up-pipe and egr cooler off and do it on a bench. i think the up-pipe will come out the top.... grind the nut square and grab it with a large crescent wrench and take it off.

just my .02

Would a Dremel Tool fit down in there to cut the nut off?. They saved me a few times.

easiest way will be to cut off the nut, remove the cooler, extract / drill and tap.


that is if you still want to go through with it.. i know the feeling of being so frustrated you just want to quit while you're ahead.

Thanks for the support guys! :beerchug: I may have to pick up a new dremel this week and try it. Really want to do this mod because I really
plan on keeping my truck a long while. Air die grinder will get the top of bolts, but is just too big and uncontrolable in this human hating confined space. Just about ready to wack the studs and remove and drill and tap.

try finding a nut breaker thats what i used on mine

good luck

I think a torch is gonna be your best bet. I just can't see a dremel cutting the nuts off when the nuts are up against the up pipe flange. It would also take a long time to do it with a dremel. My $0.02

I had your same problem and was very frustrated. I bought a socket from the Mac Tools truck, that was made to take off rounded nuts. It was kinda pricey, buy within 15 minutes I had them both off.

You have to pound the socket on, and it was fun doing that, with all that room back there. May want to give it a try before you break out the dremel.

Moved to Fuel System, Air, Exhaust, & Emissions Upgrades...