EGR Bolt Repair User Guide Text
User guide: Nino PROKIT - Ford 6.7L Power Stroke® Diesel EGR
Thank you for investing in our ProMAXX® EGR Valve Tube Repair Kit (NINO). This device was engineered to facilitate a repair, versus replacement of the manifold in the Ford 6.7L diesel engine saving you valuable time and your operation unnecessary cost.
BEFORE THE REPAIR: Depending on the size of your angle drill, you may need to move the intake manifold to the side if the bolt closest to the intake is broken. Protect all air intake passages from cutting debris before performing any machining operation.
- Remove any portion of the fastener that protrudes above the surface of the exhaust manifold prior to mounting the NINO™
ProBody™. Insert the ProBody™ flange side into the EGR passage in the exhaust manifold carefully centering the two bushing mounting holes over the 6MM tapped hole/damaged bolt(s). If only one bolt is broken, use the included ProPin™ PPP2750 for aligning the tool precisely over the damaged bolt. Using a 9/16” deep socket and ratchet or boxed end wrench, tighten the chrome hex nut until the ProBody™ stops moving. Once stable, turn an additional one-half turn or more until the ProBody™ assembly is firmly secure to the manifold.
- Insert ProBushing™ PPB5125 into the ProBody™ over the damaged bolt (Figure 1) and insert the ProDrill™ SSSC125 machine grade tooling bit just 3/8” into your drill chuck of a ½” capacity air or electric drill. Bump or toggle your drill on and off for at least five one second intervals to “seat” the tooling bit prior to drilling continually. Regulate speed to approximately 500-600 RPM for the SSSC125, and 250 RPM for both the SSSC270/420. When using the SSSC270/420, mark a depth 1 ½ inch from the cutting tip of the bit to the ProDrill™ shank with a marker or tape to control depth of cut. Place one drop of ProMAXX® ProLube™ specially formulated cutting fluid to the bushing and to the bit and manually turn your drill chuck until the tooling bit rests on the damaged bolt. Drill until your drill chuck rests on the ProBushing.
- Remove and replace the SSSC125 tooling bit with the SSSC270 bit, (or optional SSSC188/PPB5188 for faster repair times and longer bit life) the PPB5125 bushing with the PPB5270 bushing, and repeat the process above. Repeat with the SSSC420/PPB5240. Clear all debris and insert the PPB5485N ProBushing™ and attach a 3/8” drive tap holder to the ProTap™ PPT012 and apply two drops of ProMAXX® ProLube™ to the tap. Insert the ProTap™ PPT012 into the bushing, slowly and carefully turning the tap by hand first clockwise ¼ turn, then counterclockwise ¼ turn, blow down the flutes of the tap to clean debris frequently and repeat this process until the tap stops cutting.
- Remove the ProBody™ assembly by loosening the chrome hex nut and lightly tap the top of the ProArbor™ with a plasticfaced hammer to unlock it from the manifold.
- Apply one drop of Loctite® (PMXTLF014) to the PPS006B black oxide coated ProSert™. Thread the PPS006B ProSert™ onto the Insert Tool then into the manifold until it stops flush. Once locked, the manifold is now permanently repaired (Figure 2). ProMAXX® recommends adding Permatex anti-seize compound to the fasteners when re-installing the EGR tube for easier repairs in the future.
NOTE: The factory fasteners used in securing the EGR tube are an extremely hard titanium alloy compound making machining difficult. Our tooling is designed to machine the fastener. However, frequent sharpening of the tooling is recommended to keep a sharp edge and to ensure clean efficient repairs. To sharpen ProMAXX® tooling, maintain a cutting angle of 140 degrees or send them to ProMAXX® for sharpening. For even faster repairs and longer bit life, consider the optional ProMAXX® Platinum series machine tooling. Check out the Platinum PLT270 and PLT420 machine tooling bits for replacement. Platinum machine grade tooling comes standard in Platinum Plus ProKits.
Download EGR Bolt Repair User Guide
Fuel Injector Hold Down Bolt User Guide Text
USER GUIDE: Thank you for investing in the ProMAXX® NICO™ fuel injector hold-down bolt repair kit. We engineered the device to speed the repair in the
Ford 6.7L Power Stroke™ diesel engine without removing the cylinder head. Used properly, NICO™ will deliver excellent results and provide years
of reliable cost-effective repairs for you and your operation. This is a critical machining operation. It is imperative you follow the instructions
precisely to get the best results.
Remove fuel lines and fuel injectors on the engine side set for repair with the optional ProMAXX® PowerPull™ fuel injector PowerLift™ and/or
PowerHammer™ kit (see enclosed). Remove the valve cover and only those corresponding valve train components necessary to gain access to
the broken injector hold-down bolt. Cover/protect all open cylinder head cavities from cutting debris and remove any remaining portion of the
fastener that protrudes above the surface of the cylinder head so it is flush with the head. Remove any remaining debris on the cylinder head and
thoroughly clean the injector passage hole with an appropriate solvent prior to mounting the NICO ProPlate™ Assembly. Once cleaned, insert
the ProPlate™ nylon flange side down as shown below, (ProMAXX® logo down for LEFT side, ProMAXX® logo up for RIGHT side) into the injector
passage of the cylinder head carefully slipping the NICO™ assembly between two exhaust valves as shown below.
Using a 9/16” boxed wrench or deep socket and hand-operated ratchet (do not use an electric or air-powered ratchet or damage to the NICO™
expandable flange will result) and tighten the chrome hex nut (PHX375) until the ProPlate™ is securely anchored in the cylinder head so it
does not move. Once anchored, turn one-quarter to one-half additional. Insert ProBushing™ PPB2125 into the NICO™ assembly ™ until it seats
into the ProPlate™. Check the depth of an open injector hold-down bolt hole and mark your tooling bit accordingly to eliminate damage to the
cylinder head. Measure 2.00 inches from the tip of the ProMAXX® tooling drill bit up the shank and mark the dimension with a line and/or wrap
the tooling bit with tape to ensure proper clearance and avoid damage to the cylinder head. The line/tape will act as a visible depth stop for
this operation. Once set, select the included ProDrill™ SPJC125 machine tooling bit and insert it into a 3/8” capacity air or electric drill. Open
the cap on the ProLube™ PPL001 machine tap and cutting fluid and insert the small tooling bit in through the cap and gasket and retract. The
bottle is designed to deliver the right amount of oil necessary for the operation. For larger tooling and subsequent machining, place just one
drop on the end of the ProDrill™ and ProBushing™ and repeat as necessary. AVOID PENETRATING OIL/SPRAY. Insert the SPJC125 machine
tooling into the bushing first by manually turning your drill chuck with the mounted tooling bit by hand until the tooling drill rests on top of
the damaged bolt. Before drilling continuously, CRITICAL – turn/toggle/bump your drill on and off five to six one-second intervals applying
light pressure on the drill. This process will create a divot that will keep the tooling drill bit from walking, maintain precise alignment, and
allow the cutting edge to fully engage in the cutting surface. This will provide far more effective cutting action, precision, and prolong bit life.
Once complete, begin drilling continuously and regulate drilling speed to approximately 300 RPM or damage to the tooling bit may result.
Remove and replace the SPJC125 machine tooling bit with the SPJC188 bit, the PPB2125N ProBushing™ with the PPB2188O ProBushing™, and
repeat the process above. Repeat the steps once again utilizing the PPB2266O ProBushing™ and SPJC266 ProDrill™ tooling using a slower
RPM of approximately 150-250 for the largest bit. Once drilling is complete, clear all debris once again to ensure the surface is clean of all
debris. Lastly, insert the final PPB2320O ProBushing™ and using a 3/8” drive tap holder or tap handle attach to the ProTap™ PPT008 precision
machine tooling tap included. Add two drops of ProMAXX® ProLube™ drill and tapping fluid to two opposing flutes of the tap. Insert the
ProTap™ PPT008 into the bushing slowly turning the tap until it rests on the head and slowly by hand turn clockwise, then counterclockwise,
1/4 turn at a time, stopping frequently and using forced air via a blowgun, send compressed air down two opposing flutes of the tap to clear
debris. Repeat this process frequently and carefully until the tap stops cutting. DO NOT OVER-TORQUE TAP. To prolong tap life, remove and
clean debris from the tap and bushing when finished. Once complete, remove the ProPlate™ from the cylinder head by loosening the chrome hex
nut until it spins freely. It may be necessary to lightly tap the top of the ProArbor™ with a plastic-faced hammer to unlock it from the cylinder
head. In the unlikely event a tap is fractured, visit www.promaxxtool.com and purchase the ProTap™ extractor kit. For technical support, visit
www.promaxxtool.com, or call 724-941-0941.
ProMAXX® tooling included in your kit are precision-machine production grade quality made in the USA and engineered as a complete system
to ensure complete success and repair of the cylinder head without removal. It is specifically engineered to controlled precision tolerance of
(+) .000”/ (-).001” to ensure accurate and repeatable results using your new NICO™ tool. SPECIFY PROMAXX® GENUINE REPLACEMENT PARTS
AND TOOLING FOR OPTIMUM PERFORMANCE AND EXTENDED WARRANTY COVERAGE.
SAFETY PROCEDURE: ALWAYS USE APPROPRIATE SAFETY EQUIPMENT
INCLUDING OSHA APPROVED SAFETY GLASSES/GOGGLE AND PROTECTIVE
GLOVES WHILE USING THIS DEVICE AND PERFORMING THIS OPERATION
VIEW NICO USER GUIDE
Fuel Injector Puller User Guide Info
POWERPULL INSTRUCTIONS
NEED HELP? WE LOVE HELPING OUR CUSTOMERS!
DIAL 724-941-0941 We are only successful when you are.
Thank you for investing in the ProMAXX® PowerPull™ series fuel injector removal tool for the Ford® 6.7L Power Stroke™ diesel engine! This device eliminates the unnecessary step of bolting the tool to and from the cylinder head. Precision machined from hardened steel to eliminate creep, bending, cracking, or failure of the tool.
PowerPull™ Lift Kit Remove fuel line(s) and connections from the fuel injector(s) as well as the injector hold-down bolt and fork. Slip the ProLift™ knurled pad into the valve cover where the fuel injector hold-down passes through. Place the PowerLift™ assembly fork under the fuel injector and push it toward the injector until it seats and aligns with the PowerPad indent. Using a 3/8” drive ratchet with hex socket attached, turn clockwise until the injector lifts free.
PowerHammer Kit (Consists of Hammer, Slide, Acorn Nut, Impact Washer, ProAdapter™) The ProAdapter™ portion of the PowerHammer assembly shown above is designed to be used by itself to remove the injector. Simply slip a small pry bar under the ridge of the ProAdapter™ and apply leverage to remove as shown in the middle photo to the right. For a difficult injector removal, attach the ProHammer slide assembly to the ProAdapter™ as shown in the photo to the right and use quick action to remove the injector. For even more challenging injector removal, utilize both LIFT to add tension, and ProHammer to shock the injector free.
SAFETY PROCEDURE: ALWAYS USE APPROPRIATE SAFETY EQUIPMENT INCLUDING OSHA APPROVED SAFETY GLASSES/GOGGLES AND PROTECTIVE GLOVES WHILE USING THIS DEVICE AND PERFORMING THIS OPERATION.
PowerPull User Guide PDF
6.7L Power Stroke Exhaust Manifold Bolt Repair User Guide Text
FORD 6.7L POWER STROKE EXHAUST MANIFOLD REMOVE BOLT - PAYTON
Exhaust Manifold Repair
Congratulations on your purchase of a ProMAXX® engineered performance device! Our tools have the highest quality and precision in the market delivering the most productive repair. All ProMAXX® tools are manufactured in the United States of America from American materials and craftsmanship. We proudly provide limited lifetime warranties and free unlimited technical support. Need help with the repair? Contact ProMAXX Technical Support @ 724-941-0941 .
- Mount the ProPlate™ to the cylinder head using the included ProFasteners (PPF008375 or PPF008500) according to the enclosed cylinder head schematic. Torque ProFasteners to a minimum of 20 FT-LBS.
- Insert the ProBushing™ into the ProPlate™. Then insert the corresponding ProDrill™ machine grade tooling bit (included) into an air-powered, angled-style drill. Using drill depth gauge, machined into the ProPlate™, set the proper depth of the bit and mark if necessary. Apply one drop of ProLube™ (PPL001).
AVOID USING PENETRATING OIL/SPRAY OR OTHER LUBRICANTS WHICH ELEVATE CUTTING EDGE TEMPERATURES CAUSING THE BIT TO BURN AND CEASE CUTTING.
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Insert the prepared ProDrill™ into the mounted ProBushing™ by slowly and manually turning the drill chuck until the ProDrill™ slips into the bushing and makes contact with the surface of the damaged stud. (This will ensure the cutting edge is not damaged.) Repeat this procedure for each sequential step in your application.
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SET THE CUTTING EDGE: Important step to avoid drill bit breakage. While applying light pressure, activate your drill both on and off five times in one-second intervals (ten times if utilizing an air ratchet). This is the MOST CRITICAL step of this repair, creating precise alignment (a seat) for the tooling bit to stay on center and not follow the angular broken surface of the stud. Moreover, this step allows the surface of the stud to conform to the cutting edge of the bit, distributing the load evenly across the entire cutting edge, which is essential for cutting extremely hard surfaces and extending the life of the cutting tool.
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After Step 4, run the drill continuously at the proper RPM (see cutting speeds below). While the bit is turning, slightly extract the bit in and out of the damaged stud to “clean” or “excavate” cutting debris from the stud (commonly referred to as peck drilling). Repeat this step progressively, exerting more pressure until the drill reaches the marked depth.
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Inserting ProTractor (PPT125): Remove the ProPlate™ and place the optional ProCutter (PPC007A) in the drill. Insert the protruding portion of the arbor into the drilled hole. Toggle the drill on and off five times to remove the burr and clean the tapped hole. With ProTractor (PPT125), place a mark approximately ¼” from the end and lightly hammer the ProTractor (PPT125) into the remnant, to the ¼” depth line. DO NOT INSERT THE PROTRACTOR ANY FURTHER THAN 1/4" depth line. Place the included slip-nut over the ProTractor™ and slide it up against the cylinder head. While holding the opposite end of the ProTractor™ and using a high-quality calibrated torque wrench, slowly and carefully apply torque, first in the clockwise direction, and then in the counterclockwise direction to loosen the damaged stud. Repeat this motion several times NOT EXCEEDING 75 IN-LBS OF TORQUE FOR THE PPT125 OR 150 IN-LBS FOR THE PPT188. If the damaged stud fails to release, STOP and remove the ProTractor™ and proceed to the next step.
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Inserting ProTractor PPT188): using the larger (optional) ProDrill™ and corresponding ProBushing™, repeat steps 3-5 to prepare in using the larger extractor (PPT118).
NOTE: In the unlikely event an extractor fails or breaks, contact technical support at 724-941-0941 for recommendations and procedures. ProKits can also be upgraded to be an “Extractorless” repair: Repeating drilling instructions above and chasing threads clean with a machine-grade tap.
NOTE: ProMAXX® does not recommend tapered left-handed screw extractors as they have the potential to deform the remnant in the cylinder head increasing complexity of extraction. In addition, these extractors cannot be turned clockwise to unlock the damaged remnant. Approximate tooling cutting speeds (Under load): MIN: SSSC125/PLT125@500 RPM, SSSC188/PLT188@300, SSSC266/270/ PLT270@250.
NOTE: Some air ratchets may not generate sufficient RPM under load to be effective. See ProMAXX® ProRatchet PPR5260 or PowerDrill™ PPD2800 at www.promaxxtool.com for optimum efficiency and maximum productivity.
PROMAXX™ machine grade tooling is specially engineered to close tolerances of (+) .000” and (-) .001” and ground straight to ensure accurate and repeatable results in using your new device. Specify PROMAXX® genuine replacement parts and tooling for optimum performance and extended warranty coverage. Always use appropriate OSHA-approved safety glasses/goggle and protective gloves while using this device and performing this operation.
Payton User Guide PDF
