Product Overview
The iFJF Complete EGR Delete Kit for 1986–1995 Ford F-150, F-250, and Bronco is the pure mechanical solution for permanently removing the exhaust gas recirculation system from your OBS Ford truck. Unlike our simulator-based kits that use electronics to keep the check engine light off, this kit takes a different approach: physically cap both ends of the EGR circuit and eliminate the system entirely.
What makes this kit unique is the exhaust manifold cap — a component most competitors omit. While a basic block off plate only seals the intake manifold side, the iFJF kit includes a precision CNC-machined cap that threads into the exhaust manifold EGR port, allowing you to completely remove the EGR tube, valve, and all associated plumbing for a cleaner engine bay and fewer potential vacuum leak points.
Every component is manufactured from 6061-T6 billet aluminum with stainless steel hardware included. This is the most affordable EGR solution in our Ford lineup — it contains no electronic components, requires no tuning, and represents the simplest path to EGR system elimination on your 1986–1995 Ford truck. If you're building a dedicated off-road rig, trail truck, or competition vehicle where emissions compliance is not a concern, this is your kit.
Key Features
Complete Dual-End Seal — Unlike basic block off plate-only kits, the iFJF kit includes both an intake manifold block off plate AND an exhaust manifold port cap. This lets you remove the entire EGR tube assembly, valve, and vacuum lines — not just block one end.
Exhaust Manifold Cap Included — The CNC-machined aluminum cap threads into the exhaust manifold EGR port once the tube is removed, providing a permanent, leak-free seal at the hottest point in the EGR circuit. This is the component that sets our kit apart from budget alternatives.
Pure Mechanical Solution — No Electronics — This kit contains no simulator module, no wiring, and no electronic components. It's a straightforward mechanical delete. Note: Removing the EGR valve without an electronic simulator will trigger a check engine light on EEC-IV equipped vehicles. This kit is best suited for off-road-only vehicles or applications where a custom tune will handle the DTC suppression.
6061-T6 Billet Aluminum Throughout — The block off plate and exhaust cap are CNC machined from solid aerospace-grade 6061-T6 aluminum bar stock — not cast, not stamped, not extruded. This ensures precise thread engagement on the exhaust cap and a flat, warp-resistant sealing surface on the block off plate.
Complete Stainless Hardware Kit — Grade 304 stainless bolts, washers, and the exhaust cap itself are corrosion-resistant. The factory carbon steel EGR tube fitting on the exhaust manifold is frequently rusted solid — our stainless cap eliminates this failure point permanently.
Compatibility
Year Range
Make
Model
Engine
1986–1995
Ford
F-150
2.8L V6 / 4.9L I6 / 5.0L V8 / 5.8L V8 / 7.5L V8
1986–1995
Ford
F-250
4.9L I6 / 5.0L V8 / 5.8L V8 / 7.5L V8
1986–1995
Ford
F-350
4.9L I6 / 5.8L V8 / 7.5L V8
1986–1995
Ford
Bronco
4.9L I6 / 5.0L V8 / 5.8L V8
Important: This is a mechanical-only kit. It does not include an electronic EGR simulator. Vehicles with functioning EEC-IV diagnostics will illuminate the check engine light with the EGR valve electrically disconnected. For a no-CEL solution, consider our EGR Simulator Eliminator Kit.
Specifications
Block Off Plate Material: 6061-T6 billet aluminum, CNC machined
Exhaust Manifold Cap Material: 6061-T6 billet aluminum, CNC machined with pipe thread
Plate Thickness: 6.35 mm (1/4")
Surface Finish: CNC natural finish, chamfered edges
Hardware: Grade 304 stainless steel bolts, flat washers, split lock washers
Gasket: High-temperature fiber composite intake manifold gasket included
Exhaust Cap Thread: M22×1.5 (matches Ford EGR tube fitting)
Package Weight: Approximately 0.38 kg (0.84 lbs)
Package Contents: 1× billet aluminum intake block off plate, 1× billet aluminum exhaust manifold cap, 1× intake gasket, 1× stainless hardware kit, 1× copper anti-seize packet, installation guide
Installation Notes
Disconnect battery — Remove the negative cable before starting work near the starter and exhaust manifold.
Remove the EGR valve and tube — Unbolt the EGR valve from the intake manifold. Using penetrating oil on the exhaust manifold EGR tube fitting, unscrew the tube from the manifold. Expect resistance on high-mileage trucks.
Install the exhaust manifold cap — Apply the included copper anti-seize compound to the cap threads, then thread it into the exhaust manifold EGR port. Torque to 30–35 ft-lbs. Do not overtighten — the aluminum cap relies on thread engagement, not extreme torque.
Install the block off plate — Position the fiber gasket and block off plate on the intake manifold EGR flange. Torque bolts to 20–25 ft-lbs in a cross pattern.
Remove vacuum lines — Cap or remove the EGR vacuum solenoid and associated vacuum lines to prevent unmetered vacuum leaks.
Address the check engine light — The EGR valve electrical connector will remain disconnected. On EEC-IV vehicles, this will trigger a check engine light. A custom ECU tune, standalone engine management, or one of our electronic EGR simulator kits can resolve this.
Tools needed: 10 mm socket, penetrating oil (PB Blaster recommended), torque wrench, line wrench or crowfoot for the EGR tube fitting. Estimated time: 45–90 minutes depending on exhaust manifold access and bolt corrosion.
Frequently Asked Questions
Why should I choose this kit over the simulator version?
Choose this kit if you want a pure mechanical solution with zero electronic components and you don't mind addressing the check engine light through tuning or if your vehicle is trailered/off-road only. It's also our most affordable EGR solution and includes the exhaust manifold cap that the simulator kits do not. Choose our simulator kit if keeping the CEL off without tuning is your priority.
Will this kit cause a check engine light?
Yes — this is a mechanical-only kit. When you disconnect the EGR valve electrical connector, the Ford EEC-IV computer will detect the open circuit and illuminate the check engine light, typically setting codes P0405 or P1405. This kit is ideal for off-road vehicles, dedicated race trucks, or applications where you're running a standalone ECU or custom tune that suppresses EGR DTCs.
What makes the exhaust manifold cap important?
The exhaust manifold port is the hot side of the EGR circuit — it sees direct exhaust gas at temperatures exceeding 1,000°F. Without a proper cap, this port becomes a major exhaust leak. Many budget kits only include the intake block off plate and leave you to source a cap separately. Our kit includes a purpose-machined 6061-T6 aluminum cap designed for this exact application.
Can I install this on my 1993 F-150 5.0L?
Yes. The 1993 F-150 5.0L (302) is a direct fit. The exhaust manifold cap will thread into the EGR tube port on the passenger-side exhaust manifold, and the block off plate will seal the intake manifold EGR port on the throttle body side of the upper intake.
Does this fit the Ford 7.5L (460) big block?
Yes. The 460 (7.5L) V8 in F-250 and F-350 applications is fully supported. The EGR tube on the 460 runs from the passenger-side exhaust manifold to the intake — our cap fits the manifold port, and our block off plate fits the intake EGR flange.
Do I need a tune after installing this kit?
A tune is not required for the engine to run properly after installing this kit — the mechanical deletion does not affect fuel delivery or ignition timing. However, a custom tune is required if you want to prevent the check engine light and pass OBD-based emissions readiness checks. For a no-tune solution, see our EGR simulator kit.
What's included that I won't get with cheaper kits?
Most budget EGR delete kits include only a stamped steel intake block off plate — sometimes without a gasket or hardware. The iFJF kit includes: (1) CNC billet 6061-T6 intake block off plate, (2) CNC billet 6061-T6 exhaust manifold cap, (3) high-temperature fiber gasket, (4) full stainless steel hardware kit, and (5) copper anti-seize for the exhaust cap installation. You get everything needed to complete the job properly.
📖 Learn More: Ford EGR Delete Guide
Not sure which EGR solution is right for your Ford? Read our Complete EGR Delete Guide for 1986–1995 OBS Fords — covering cost comparison, installation walkthrough, legal considerations, and compatibility across all engine families.
⚠️ Off-Road Use Only
This complete EGR delete kit is intended exclusively for off-road, racing, and competition vehicles not operated on public highways. Removing or disabling emissions control systems on street-driven vehicles is a violation of the federal Clean Air Act (42 U.S.C. §7522) and may carry significant penalties. The purchaser accepts all responsibility for determining the legality of installation and use. iFJF shall not be held liable for any damages, fines, or legal consequences resulting from the use of this product.
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