After reading most of the threads on cleaning it seems to be a toss up about disconnecting the batteries before unplugging the EGR. I rather not disconnect & have to relearn. What's the OH shi.... side of not disconnecting the batteries?

 

I've cleaned mine before without disconnecting the batteries. Didn't have any unexpected surprises.

 

Just pulled and cleaned mine this past weekend. I didn't disconnect the batteries. Everything is running good, no codes or anything. I can't recall reading anywhere that the batteries need to be disconnected to clean the EGR valve?

 

I've never heard of disconnecting the batteries either, and I've cleaned mine 4 or 5 times. Heck, I don't even disconnect both batteries at the same time when changing them. Here is a good link to cleaning the egr valve though...
6.0L EGR Valve Cleaning - DTS Articles - Articles - Articles - DTS

 

Just don't get any fluid in the little holes on the bottom of the sensor.

Baby food jars are a good depth, fill with carb cleaner and stick it in the jar.


As for batteries, when ever I'm working in the engine compartment, I throw a heavy towel or rag over them so I don't lay a wrench on the terminals!