Help--EGR replaced...still have problem
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Senior User
Joined: Apr 2005
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From: southern swamps
Help--EGR replaced...still have problem
Hey all,
I have a 2005 F350 6.0 and about a week ago it started to sound muffled/low upon start. A few days ago after starting it quit when I shifted into reverse...I waited, started again, waited 30 seconds and shifted and it was okay. Since then it has surged a few times while idling at red lights...and yesterday at bank drive-thru it wanted to quit while idling and I had to keep revving it up...went to the Ford place and they put it on the machine and said I had a bad EGR valve and they replaced it...$520 later...it was running in the bay when I got it and left...they closed right behind me.
When I left, ran a few more errands, each time I started it there was that same low muffled sound...still there...this morning, same thing, and also it is still/again idling funny...first low, then tries to surge...I called them and they said if it keeps up to bring it back in.
What else could this be? Might the EGR they put on be bad? Any other options?
I keep my truck well maintained, it is due right now for oil change and filters change but it is not overdue.
Thanks in advance for any advice and thoughts y'all can give me...
I appreciate it!
I have a 2005 F350 6.0 and about a week ago it started to sound muffled/low upon start. A few days ago after starting it quit when I shifted into reverse...I waited, started again, waited 30 seconds and shifted and it was okay. Since then it has surged a few times while idling at red lights...and yesterday at bank drive-thru it wanted to quit while idling and I had to keep revving it up...went to the Ford place and they put it on the machine and said I had a bad EGR valve and they replaced it...$520 later...it was running in the bay when I got it and left...they closed right behind me.
When I left, ran a few more errands, each time I started it there was that same low muffled sound...still there...this morning, same thing, and also it is still/again idling funny...first low, then tries to surge...I called them and they said if it keeps up to bring it back in.
What else could this be? Might the EGR they put on be bad? Any other options?
I keep my truck well maintained, it is due right now for oil change and filters change but it is not overdue.
Thanks in advance for any advice and thoughts y'all can give me...
I appreciate it!
Hotshot
Joined: Aug 2006
Posts: 17,398
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From: Whittier, CA
First of all, the EGR replacement should have been free, unless you have over 100k miles on the truck. What did they charge you for?
Second, there was a recent batch of bad EGR valves, so it could be bad out of the box. Of course, any component can be bad out of the box anyway.
Second, there was a recent batch of bad EGR valves, so it could be bad out of the box. Of course, any component can be bad out of the box anyway.
Thread Starter
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Senior User
Joined: Apr 2005
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From: southern swamps
Yes, it has over (not much) 100K unfortunate for me 
It's getting worse through this day, just shut off again, am going back to Ford at 3 p.m...any more thoughts before then, hope to hear from you and anyone!
THANKS MUCH
It's getting worse through this day, just shut off again, am going back to Ford at 3 p.m...any more thoughts before then, hope to hear from you and anyone!
THANKS MUCH
Elder User
Joined: Sep 2007
Posts: 803
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From: S CAL
You should have them put a scanner on it to look for any hidden diagnostic trouble codes. They do not always set a light on the dash. You could unplug the egr also and see if the problem goes away. It could also be a bad egr just like bpounds said.
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Senior User
Joined: Apr 2005
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From: southern swamps
Thanks to each of you 
I went back today and they said the machine (scanner?) showed or "threw" bad EGR codes and they said it was nasty in under a day and replaced it again...and put in a whole bottle of cetane boost...and said if it "throws" bad EGR codes again the intake will have to be replaced. ???
I go to the airport at 5 a.m. so hopefully it will get there safely; I won't be back until Monday afternoon but will report on how it's doing early next week.
THANKS again...if it acts up on the way to airport I'll post from somewhere over the weekend.
I went back today and they said the machine (scanner?) showed or "threw" bad EGR codes and they said it was nasty in under a day and replaced it again...and put in a whole bottle of cetane boost...and said if it "throws" bad EGR codes again the intake will have to be replaced. ???
I go to the airport at 5 a.m. so hopefully it will get there safely; I won't be back until Monday afternoon but will report on how it's doing early next week.
THANKS again...if it acts up on the way to airport I'll post from somewhere over the weekend.
Cargo Master
Joined: Oct 2005
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From: Farmington NM
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We had a similar problem and they replaced the tubes going from and to the EGR. They also reset the computer on our truck as we do alot of idleing. When the truck is idleing for a long time it bypasses the EGR so then the EGR won't get plugged up too bad.
Hope this info helps. Ours is a F250 2004 diesel.
Hope this info helps. Ours is a F250 2004 diesel.
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Senior User
Joined: Apr 2005
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From: southern swamps
...Wouldn't start the morning I had to go to airport, finally did...essentially...Problems when I left Thursday a.m. First, It didn't want to start, at all. Then, it ran rough to airport and idled poorly.
Now 2 EGR valves and they are saying if that second one didn't fix the problem, I will need a new intake. Help...
Thanks for the tip on the tubes to/from EGR...
Now 2 EGR valves and they are saying if that second one didn't fix the problem, I will need a new intake. Help...
Thanks for the tip on the tubes to/from EGR...
Senior User
Joined: Jun 2005
Posts: 115
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From: SoCal
On my truck...03 F350 SD, the EGR sits in the intake and I don't see any tubes. Can I block the EGR at its origin closer to the exhaust? My truck has 48,000mi and I just did the 2nd EGR. Guess what...leave the dealership and the check engine light comes on before I even get home. Call the dealer the next day and they say I have to remove my aftermarket air filter and exhaust to rule those out as reason the check engine light is on. I ask the dealer what codes they see and they report P0401, 403, 405 which are all EGR codes so I ask what the heck my air filter or exhaust has to do with anything. They won't budge, I even took it up with the manager. So my options are, spend time un-modding and go back to have the dealer fix their problem, or un-plug the EGR (which I probably will do anyway). I only worry about driving the truck with the check light on crying wolf.
Ford dealerships - I think they purposedly train their service writers as first line of defense. What do you expect for $3.00 stock price.
Ford dealerships - I think they purposedly train their service writers as first line of defense. What do you expect for $3.00 stock price.
Elder User
Joined: Sep 2007
Posts: 803
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From: S CAL
[quote=drewworm;6842925]On my truck...03 F350 SD, the EGR sits in the intake and I don't see any tubes. Can I block the EGR at its origin closer to the exhaust? My truck has 48,000mi and I just did the 2nd EGR. Guess what...leave the dealership and the check engine light comes on before I even get home. Call the dealer the next day and they say I have to remove my aftermarket air filter and exhaust to rule those out as reason the check engine light is on. I ask the dealer what codes they see and they report P0401, 403, 405 which are all EGR codes so I ask what the heck my air filter or exhaust has to do with anything. They won't budge, I even took it up with the manager. So my options are, spend time un-modding and go back to have the dealer fix their problem, or un-plug the EGR (which I probably will do anyway). I only worry about driving the truck with the check light on crying wolf.
I would try a different dealership. The air filter and exhaust do not affect the egr performance.
I would try a different dealership. The air filter and exhaust do not affect the egr performance.
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From: southern swamps
Backing up (mine didn't have tubes either, as it turns out) the dealer did end up replacing the intake. At the time, they recommended replacing the cooler, too, although it was checking out fine...but the repair was already more than I could stand, having already done all this other stuff with EGR valve etc...so, even though I'll have to pay labor all over again if the cooler goes out, I couldn't swing it at the same time as intake.
Since then, my truck has been working fine. Fingers crossed...but back to the same old truck that I'm happy with.
Although I have (as of last few mornings) a whining fan sound when I start the truck. I'll make another post about that.
Since then, my truck has been working fine. Fingers crossed...but back to the same old truck that I'm happy with.
Although I have (as of last few mornings) a whining fan sound when I start the truck. I'll make another post about that.