Just a layman observation here but, it seems that those of us who may have accidently or mysteriously been inflicted with the unplugged EGR valve syndrome have had fewer or no problems in a lot of different areas.

This freak occurence has even resolved a couple of issues I hear.

This is what I do not understand. Activated bad EGR's need replaced...sometimes often. Unplug a good one (in closed postion of course) and with the possible exception of CA..there seems to be no negative effect. In fact engine seems to benefit.

Are the bad EGR's that are creating problems sticking in the open position? Is this why a bad EGR has a negative affect on the engine? If the bad EGR is sticking in the closed position then who cares? Right or wrong?

 

Being stuck in the closed position will not be bad from not having exhaust rerouted into your intake. (kind of a repulsive thought). That being said, the PCM will sense an out of range condition with the EGR and not take advantage of normal programming. Instead, the PCM will adopt a preset strategy to run assuming the EGR is malfunctioning. I don't know what the engineers set up as the alternative strategy. Is the alternative a slight detuning? I think the only way to have the PCM to operate correctly is to have a normally functioning EGR plugged in.

 

Being stuck in the closed position will not be bad from not having exhaust rerouted into your intake. (kind of a repulsive thought).

I do know one thing for ding dang sure...If my exhaust was rerouted into my intake I would have a REALLY, REALLY, bad day. If you know what I mean.

 

So, the question remains, we'll figure it safe to assume that a faulty EGR movement, (gummed up), or return signal to the PCM will cause an adopted preset strategy of fuel/air management. Degraded performance is sure to be the result.

But, how does the PCM handle a "no EGR signal at all" situation? There are reports that unplugging the EGR valve in the closed position solves many run condition problems. Why?

My04beast, did you get any of the failed EGR valves back from the service department? I'd wonder if we can't take one apart to disconnect the butterfly from what ever shaft moves it. Tack weld it closed, but allow the shaft to move freely thus allow the position sensor, (or feedback from a solenoid), send the correct, (lying to it), signal back to the PCM and what ever other sensor needs it's information. Know what I mean? Keep all flow closed, but make the other sensors think that it's working fine.

(I described it as a butterfly valve, yet I've not even set eyes on mine. I hope that's an accurate description) I've acually done this on Gas engines with a diphram EGR valve that worked fine. All I did was install a blockoff plate down stream at the manifold. The computer figured all was well because the valve still moved and sent signal back to the computer.

 

...great thought, Steve....interesting to know what it looks like inside.

 

there is a somewhat random sampling of 6.0's that even have the "flapper" in em. mine did not. some do have em, and even weirder, some have em and they dont do anything.


the very first thing i did to my truck was disconnect the egr. i have had ZERO problems, and the local ford dealership i used to work at, and still take my truck to for service, has been actually disconnecting egr's on all the 6.0's that are in the lot and any that come in for service.
i wont mention any names. the egr system on new diesels was put in force to lower emmissions in OTR trucks, and is actually making the problem worse.
none of the systems is working the way they were intended, so its not just the 6.0. it will take a decade to work the bugs out of the new fancy POS systems, and until then, my egr will be unplugged, and my exhaust will be without a catalyst.

it would behoove you to do the same

 

See here for EGR valve:

http://www.backglass.org/duncan/ps60...l/ps60_037.jpg

 

If I would have designed it, it would have been. (Maybe that's why I'm not an engineer...)

So, who's got a Ford engineer in their back pocket? What's the signal interpreted as, (if disconnected), back at the PCM? Computer fault -yes. No "Check Engine Light"?

And which one of you is standing in front of your milling machine fabricating an EGR blank off plate?

I'm quite surprised that a dealership service department is disconnecting EGR's.

I almost wonder if more EGR valves fail on Automatics, than on Manual transmission equiped trucks. (Percentages)

 

My truck continues to have the surging, rough idle (cutting off occasionally) condition in spite of the new EGR valve UNPLUGGED. I think every sensor on the truck has now been replaced. I've written and sent letters to Ford to start the lemon law process and also to Gale Banks asking for their help with removing their six gun bundle and returning the truck to it's stock config.

I'll post updates as this process unfolds.

 

A rep from Gale Banks Engineering finally called me back. They claim their six gun bundle is not the problem with my truck as Ford claims. The rep got a real attitude with me on the phone and stated that my problem was not on "his agenda". Now I'm caught in the middle of Gale Banks Engineering and Ford Motor Co. pointing fingers at each other for the problem my truck has.

I hope each member of FTE can learn by my mistake. I would definitely not recommend a Gale Banks chip or performance system. If anyone out there is considering this installation, please consider that Bank's dealers are in no way responsible for warranty issues, YOU are. If there is a problem, you pay them to correct it! It is too permanent an installation and Gale Banks customer service absolutely sucks. If I could start over, would go with the Diablo Predator or Superchips products. Simple to install and easily removable.

Now, instead of enjoying what should be my new "dream truck", I am instead stuck with a POS truck and caught between two companies with poor customer service and claiming no responsibility whatsoever.

 

Really sorry to hear all the problems...I see finger pointing all the time when one of my customers purchases part of my system and part of a competitors system to try and save a few $$$...when something fails it usually boils down to incompatability with some component that does not speak the same language.

I just did a really, really quick review of all the posts here...and I apologize in advance for asking....but, has the oil level been checked and is it at mid level hatch marks or below on the dip stick? I just had to ask.

Good luck.

 

I installed a total six gun bundle from Banks to avoid mixing a matching and having a possible problem. Bank's claimed their system was dependable and totallty safe to install, yet Ford Motor Company claims my problem is the result of their product and they don't seem to care. I THINK the problem I have is Ford's, but I am very disappointed with the way Banks has handled the fact that Ford has pointed the finger at them. No fact-finding, no "let's help this customer" type of attitude. Hell, they will not even return calls.

I just hope Ford makes good for me so my confidence and 22+ years of loyalty can be preserved.

As for the oil level, that is an issue. The second time my truck was in for "my" warranty issue they drained some oil from the pan. I received no explanatuion other than there was a possible "foaming" problem. My oil has been changed twice since then at the same dealership, so i hope they know what level to fill it to. I'll check the level anyway and let you know.

 

my04beast, yes, you could have a problem with your 6.0 notwithstanding the Banks package. Once you installed the Banks you are on your own. I would return it to stock and fix the problem.

Banks will quote the Magnussen Moss Act until the cows come home. But that will not do you any good. Ford just has to say that the Banks system does not "meet or exceed" Ford specs. Ford does not void your warranty, they just deny the claim for your warranty issue.

There are standard diagnostic charts for the symptoms you describe. But if you change the the truck with those mods, you change the operating parameters for the truck.

Again, I would return it to stock and have them diagnose the probem. There are several sensors and components that could be causing you the problem.

 

Well written Steve, and true.

 

Steve,

Thanks for the good advice. I definitely learned a lesson with all this. probably a very expensive lesson! I am in the process of returning the truck to stock. I am also getting advice from a lemon law lawyer. I'll keep you posted.