2 Years, 3 EGR valves. Is there something else wrong? Is there something else I should do?

 

Breath slowly, everything is going to be fine.

First: Try running the truck with the EGR unplugged.
Second: Modify the EGR up-pipe.
Third: Post results and WELCOME TO FTE!!!!

 

6.0's tend to have this problem there is a thread somewhere around here with some pretty nasty pics of his EGR after 11,000 miles. CAKED in nasty stuff. Goodluck

 

Yup...it should be cleaned regularly w/carb cleaner (not brake cleaner) to avoid havng to replace it. hth

 

Ford came out with a TSB saying not to clean the EGR but only to replace it. Ya easy to say when your not dishing out the money. lol

 

Modify????

 

Check out the tech folder, there is a whole page on Removing the EGR valve / system

 

Come over to the Dark Side and feel the power....................................

Modding the EGR up-pipe you will block off the passage that feeds the exhaust flow to the EGR. This allows you to feed more ehxaust flow the turbo and NOT allow exhaust to the EGR valve thus eliminating the soot to collect around the EGR valve.

 

Where do you get this pipe, and how difficult is the process? Since your modifying the up pipe, I assume you go ahead and leave the egr plugged in?

 

Where do you get this mod and how difficult is it to do? Since you are modifying the pipe, I assume you leave the egr plugged in? How does this affect your turbo in the long run?

 

Basically you can do the grunt work yourself OR pay out the wazoo for some overpriced pipe.

There is some wrench/rachet turning required in some hard to reach areas behind the turbo.

This is the short version: Remove turbo down pipe (helps for space), remove EGR up-pipe clamp to EGR cooler, remove the up-pipe. Then some welding is required to plug the "T" fitting, then reinstall everything you took off.

Some have removed the passenger wheel well liner for space as well. Having skinny arms and an extra set of hands helps.

You can see the EGR up-pipe on the right side of this motor. It comes off the passenger side exhaust manifold, has the "T" connecting to the EGR cooler and then connects to the turbo y-pipe. You will need to disconnect all the mounting hardware and clamp. This can be done in the driveway.

http://i18.ebayimg.com/06/i/000/c3/f9/85b6_3.JPG
http://i11.ebayimg.com/07/i/000/c3/f9/882a_3.JPG

 

Yup...there Service departments are hurting for business so they'd much rather replace it and have you spend $170+ for a new valve rather than clean it yourself and not have to spend that money. Funny how that works

 

Heavy - any alternatives to welding? Im not really ready for that yet!

 

C'mon...we all have had to let go of the apron strings at some point. Don't tell me you are holding on still..................


Just kidding. You can order a second pipe, weld it up and then if you need to swap back in the OEM pipe.

There is really only a few ways to do this.....

 

Ah gotcha. i got all the tools to weld but still hesitant on actually doing it to my truck. maybe ill screw around with some scrap metals first. thanx