EGR removal
1. never remove the EGR valve when motor is hot
2. the two bolts out of manafold are 8mm and they are different lenght the left bolt is longer than the right just an heads up
3. Gasket kit from ford #3c3z-9p455-AB come with two O-rings and plate gasket for around $15.00
4. the plate gasket has inter ***** that wont fit right so by slideing it over the sharp egr and twist they will be cut off by the egr houseing.Insteed of a knife
5. I used some 3m double back tape to hold the smaller bolt to the socket so I didnt have to remove anything the larger bolt can be twisted in by hand.
I have some pics but again, not able to get photobucket and my pics together.I can e-mail them if somebody can show what my Nasty EGR valve looks like.with about 1/8'' of soot at the bottom.
6. I also used ( for the second time ) my wifes walnut pick,I didnt say that too loud did I, for the o-ring take off and to level out the plate gasket also to remove soot from the intake, a small plumbers soldering brush to clean and used carb cleaner while covering the electrical plug side of egr being carefull not to spray that.I also Vaccumed the port scraped and vaccumed
7. This was a pretty easy job around 45 min ,It took me longer to find my keys than it did the whole job,so when I can I will post some pics.
1 Stalling
2 bucking
3. driveing and then surge ( high ,low boost).
4. stoped at light surge truck jumps
This is will be the EGR Valve and needs to be cleaned of soot build up,
If the problem remains
5. go to Map senser connection to Intake and clean connection and hose
6.. ICP ,make sure the sencer is not leaking ( back side electrical connect of oil )
7. Icp Wire connection /Pig tail - the short in the 90deg wire gets hot and shorts out . while truck running wiggle test this will tell you that pig tail is needed.








