Ok here's the scenario.

I have an F250 Light duty with the 5.4 liter. I've had it for about 2 years now.

last year i found that it had a slight exhaust leak from the left side manifold saw that the studs where breaking off i wasn't worried about it until i found that the manifold to pipe studs where like toothpicks and ready to break.

I broke down and replaced both manifolds and the EGR tube which was rusty etc.

anyways 2 days after i got it back together the check engine light came on for the insufficient egr flow.

I just reset it and in about 20 miles it came back on, i looked around on the net to find some obvious answers.

checked the pipe connections, let me to start replacing components.
I had replaced the DPFE sensor, the hoses, the egr valve itself the vacuum solenoid and i've even taken the throttle body off and cleaned out the ports and installed new gaskets.

i've replaced the hoses 3 or 4 times now because they are the crappy dorman brand and i can't find them in any other brand.
the first time i tried cutting them to the right length and the inside of the hose collasped and i couldn't use it.
second time the light stayed off for awhile not for sure mileage wise cause this isn't my primary vehicle.
but it keeps persisting, even tried putting clamps on the hoses and the problem still persists.

what would cause it to have a reoccuring code after i installed new manifolds and an EGR tube?

I'm so frustrated with this i just want the engine light to say off.

anyone with this kind of issue?

thanks for reading.

 

Are the 2 little hoses in the right port?, they should not cross, and one is a different size
Next Ive seen new egr tubes with bad orfices between the tubes especially aftermarkets
Next I would due a suck test on the egr with your mouth and a extra vac line see if engine slows or stalls
Then put vac gauge on egr tube lines, see if you get a psi reading, then vac reading reving engine, checking for tube or orfice blockage

 

yeah i think i might leaning toward the egr tube issue as well.


I know the hoses are on correctly.

i try checking the egr manually and see what happens.

thanks.

 

You need to identify the year of your truck. Also, post the exact DTC since we're not psychic.

EGR faults are among the most commonly posted problems. Plug your DTC in the search tool and you'll likely find dozens or even hundreds of posts discussing certain fault codes.

 

wonder if you got a hole rusted in the bottom of your canister on the inner fender? Think you have one there.