I have a 99 Expy 5.4 EB with a bunch of miles (115K). Within the last 2-3 weeks it has started to clatter immediately after start-up when put in reverse or drive. Sounds like a diesel or noisy lifter, but curiously it practically goes away when shifted back into neutral or park. Then when moving under slow but steady throttle, it runs rough and feels like something big is tugging on it from behind (silly analagy but translates) - then when more throttle is applied the ride smooths out and the clatter goes away...this is over a period of about 30 seconds.

To compound matters...about 5 days ago the "Service Engine Soon" light came on. Tonight after reading one of the forum threads I learned I could take the car to Advance Auto to have the codes read for free. I drove there and was told ithe codes read #401 Insufficient Emission Gas Recovery and #402 Excessive Emission Gas Recovery. They cleared the codes which did not reoccur on the 15 minute drive back home. The guy that helped me said the problem must be the EGR Valve.

Can the EGR valve be rebuilt? Is it a simple matter of carbon build-up fouling the valve? Advance Auto said the EGR valve is a couple of hundred dollar dealer part...is that correct... or are there more economical options on-line?

Is it very likey that the two conditions are related?

Thanks in advance to anyone who can shed some light on this for me.

 

I'm having the same 401 and 402 codes and the feeling of a stumble or tugging at about 35 MPH under light throttle conditions ........... are there simple tests that can be done to the EGR valve / vacuum lines / control device to determine the actual fault?

Also ..... the EGR valve appears to be buried badly at the top back of the engine ...... under the fire wall ....... this can't be fun ..... any help is appreciated.

 

It's very rarely the valve and plus if it was the valve then it would have insuficient egr flow detected. It's probably your dpfe that is stuck at a higher voltage, they either fail at no volts, insuficient flow, or higher voltage 2.6 or so, when the voltage is up it tells a solenoid to pull a target vacuum open the egr valve hence letting in exhaust gas prematurely, that is why you feel it at an idle, and when you rev it up it gets smooth because it's mixing at the right ratio. So get them at autozone if they know how to do it, to pull up the pids for the dpfegr and read the voltage, at idle it should be around 1 volt and then up to about 3/8 trottle it will rise to about 4 to 4.5 volts at the most, it it is real low like below .9 volts or stays at a higher voltage all the time then you need a new dpfegr.

 

I have a 1999 F250 V10 that idles & runs great. It started to bog down like it is flooding, (or missing) when you barely step on the gas in gear. The check engine light came on. I went to Autozone for the test. It read that the egr has insufficent flow. I took the egr off & checked it. It was clean. I hooked up a vacuum cleaner to it & the valve moves up & down freely. I reinstalled it & hooked the battery back up. The check engine light was off. Next day the light went back on. It has 71500 miles on it. I had it since 8/98. ???

 

It's probably your dpfegr then.