What is the trick to get it out? Mine feels stuck as could be. Thanks

 

Ok, I got it out, now what should I use to clean it?

 

I have always used brake cleaner. Just make sure you remove the 2 rubber o-rings before you start cleaning.

 

how do you put it back in once you clean it? does it screw in or just pop back in place? Where do you buy a new gasket? How much is a new EGR valve?

 

Just push it back in place. It does not screw in. Ford has the O-rings. If you are careful during removal you can reuse them.

 

so no gasket is needed for the EGR on a 04 F-350? where is the EGR located on the engine?

 

In addition to the orings, there is a gasket that can be re-used, if in good condition (probably no reason why it shouldn't be in good condition).

EGR O-ring kit number is 3C3Z-9P455-AB or International # 1840778C92; EGR bolts are torqued to 13 Nm

Also - regarding the cleaning fluid ....................

At about 1:40 seconds into the Ford video below, they make the recommendation to not use brake cleaner:
<TABLE style="WIDTH: 327pt; BORDER-COLLAPSE: collapse" cellSpacing=0 cellPadding=0 width=436 border=0 x:str><COLGROUP><COL style="WIDTH: 327pt; mso-width-source: userset; mso-width-alt: 15945" width=436><TBODY><TR style="HEIGHT: 25.5pt" height=34><TD class=xl24 style="BORDER-LEFT-COLOR: #d4d0c8; BORDER-BOTTOM-COLOR: #d4d0c8; WIDTH: 327pt; BORDER-TOP-COLOR: #d4d0c8; HEIGHT: 25.5pt; BACKGROUND-COLOR: yellow; BORDER-RIGHT-COLOR: #d4d0c8" width=436 height=34>mms://multimedia.ford.com/seopts/Tech_31_250k.wmv</TD></TR></TBODY></TABLE>

Also:
<TABLE style="WIDTH: 660pt; BORDER-COLLAPSE: collapse" cellSpacing=0 cellPadding=0 width=880 border=0 x:str><COLGROUP><COL style="WIDTH: 660pt; mso-width-source: userset; mso-width-alt: 32182" width=880><TBODY><TR style="HEIGHT: 12.75pt" height=17><TD class=xl24 style="BORDER-TOP: windowtext 0.5pt solid; BORDER-LEFT: windowtext 1pt solid; WIDTH: 660pt; BORDER-BOTTOM: windowtext 0.5pt solid; HEIGHT: 12.75pt; BACKGROUND-COLOR: silver; BORDER-RIGHT-COLOR: #d4d0c8" width=880 height=17>Carb Cleaner recommendation (see link below and refer to old TSB 06-19-6):</TD></TR><TR style="HEIGHT: 12.75pt" height=17><TD class=xl25 style="BORDER-LEFT-COLOR: #d4d0c8; BORDER-BOTTOM-COLOR: #d4d0c8; BORDER-TOP-COLOR: #d4d0c8; HEIGHT: 12.75pt; BACKGROUND-COLOR: silver; BORDER-RIGHT-COLOR: #d4d0c8" height=17>http://www.forddoctorsdts.com/articles/article-06-12.php</TD></TR></TBODY></TABLE>

 

why does my EGR valve appear to have to bolts holding it in place? Am I looking in the correct place? it is towards the front of the engine on the top?

 

It's right behind the elbow on the intake. Should have two bolts holding it in place.