When you clean the EGR, make sure you do it properly:

Clean it - Use Carb cleaner, not brake cleaner - keep the fluid out of the weep holes. Use new O-Rings (kit number is 3C3Z-9P455-AB).

ALSO: Clean EBP tube (vehicles built before 9/23/03 have the EBP sensor taken out of the computer control strategy), Also clean MAP sensor hose and manifold opening.

If you have a problem getting the valve out, take the 2 8mm bolts out, spin the valve by hand, and use two lady fingers or heel bars (or something similar) depending where you live (1 under each tab) and pop it right out. Some folks use wire on each tab and a broom handle.

When you go to install the valve it is normal for the valve not to go all the way in. Push it as far as you can and use the bolts to suck it in.

Here is some reading on the EGR
<TABLE style="WIDTH: 568pt; BORDER-COLLAPSE: collapse" cellSpacing=0 cellPadding=0 width=757 border=0 x:str><COLGROUP><COL style="WIDTH: 568pt; mso-width-source: userset; mso-width-alt: 27684" width=757><TBODY><TR style="HEIGHT: 33.75pt" height=45><TD class=xl24 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; WIDTH: 568pt; BORDER-BOTTOM: #d4d0c8; HEIGHT: 33.75pt; BACKGROUND-COLOR: transparent" width=757 height=45>http://www.intellidog.com/dieselmann/60bulletin.htm</TD></TR><TR style="HEIGHT: 12.75pt" height=17><TD class=xl26 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; BORDER-BOTTOM: #d4d0c8; HEIGHT: 12.75pt; BACKGROUND-COLOR: transparent" height=17>http://www.forddoctorsdts.com/articles/article-05-15.php</TD></TR><TR style="HEIGHT: 11.25pt" height=15><TD class=xl26 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; BORDER-BOTTOM: #d4d0c8; HEIGHT: 11.25pt; BACKGROUND-COLOR: transparent" height=15>http://www.forddoctorsdts.com/articles/article-06-12.php</TD></TR><TR style="HEIGHT: 12.75pt" height=17><TD class=xl26 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; BORDER-BOTTOM: #d4d0c8; HEIGHT: 12.75pt; BACKGROUND-COLOR: transparent" height=17>https://www.ford-trucks.com/forums/705899-more-egr-stuff-w-pics.html</TD></TR><TR style="HEIGHT: 12.75pt" height=17><TD class=xl26 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; BORDER-BOTTOM: #d4d0c8; HEIGHT: 12.75pt; BACKGROUND-COLOR: transparent" height=17>https://www.ford-trucks.com/forums/449995-scary-pics-of-my-11-000-mile-old-egr-valve.html</TD></TR><TR style="HEIGHT: 12.75pt" height=17><TD class=xl26 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; BORDER-BOTTOM: #d4d0c8; HEIGHT: 12.75pt; BACKGROUND-COLOR: transparent" height=17>https://www.ford-trucks.com/forums/698376-egr-disconnect-2.html</TD></TR><TR style="HEIGHT: 12.75pt" height=17><TD class=xl25 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; BORDER-BOTTOM: #d4d0c8; HEIGHT: 12.75pt; BACKGROUND-COLOR: transparent" height=17>https://www.ford-trucks.com/forums/721923-sluggish-off-start-blowing-smoke.html</TD></TR><TR style="HEIGHT: 12.75pt" height=17><TD class=xl25 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; BORDER-BOTTOM: #d4d0c8; HEIGHT: 12.75pt; BACKGROUND-COLOR: transparent" height=17>https://www.ford-trucks.com/forums/f24/ebp-pipe-location-cleaning-advice-146925/</TD></TR><TR style="HEIGHT: 12.75pt" height=17><TD class=xl25 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; BORDER-BOTTOM: #d4d0c8; HEIGHT: 12.75pt; BACKGROUND-COLOR: transparent" height=17></TD></TR></TBODY></TABLE>

 

You ought to be able to tow that trailer at a decent grade doing 80 in 5th gear doing 2200 RPMS and boost at 22 lbs withough having to downshift.

I can tow my 33' 13K lb fifth wheel at a decent grade for a good while all while staying in the 2K RPM range without down shifting. When the engine feels it cannot sustain speed with the power it's producing in 5th gear, it will eventually downshift into 4th.

 

Well i pulled my egr valve and it looked like it was dipped in tar (40000km). There was no dry soot just a sticky tar like substance. I cleaned it up and put it back i hope to see a difference the next time i tow. Thanks again for all the helpful advice.

 

mroberge7- One thing you and the rest of the diesel owners on here might try is a product called Lucas oil. Lucas makes an oil additive that helps with fuel economy, longeveity, and thermal breakdown, especially in turbo charged engines. This additive helps to prevent sludge and varnish, keeps parts lubed for cold starts, especially the turbo, and can extend oil change intervals without voiding any warranties. Lucas also makes a fuel additive that is second to none! Noticable improvement in mileage, power, emission reductions, injector wear and carbon buildup in egr and cat systems. I have been using lucas products in my ford diesels since 1985 and also in my heavy duty cat diesels, and no one will convince me they arent helping. The improvements can be documented with ease! I currently have a 3406E cat that I just overhauled at 1436000 miles, a C-15 that is approaching 1136000 miles and my 1990 f250 that had 289000 miles before the trans let go.