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EGR Problems

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Old Nov 5, 2009 | 11:44 AM
  #1  
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2004SD
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From: Oxford
EGR Problems

Thanks in advance for any help. My EGR valve has been sticking occasionally and this weekend while on a trip I finally unplugged it. The pickup ran great the rest of the trip. I took it in to the dealer to get it looked at for this and a couple other reasons. They called and said that the oil cooler is plugging up which is restricting air flow to the egr cooler, causing the egr valve to soot up. The pickup is an 04 cc 4x4 with 76,0000 miles on it. Turns out I am 30 days out of my warranty coverage and they said it would cost $2,400. They have talked to ford about covering it and while we are waiting to hear, I thought I would ask the fte professionals if their explaination sounds reasonable and if they won't fix it under warranty, is there a better, more cost affective fix?
 
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Old Nov 5, 2009 | 03:12 PM
  #2  
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jmaskew
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From: Henderson, NV
Originally Posted by 2004SD
Thanks in advance for any help. My EGR valve has been sticking occasionally and this weekend while on a trip I finally unplugged it. The pickup ran great the rest of the trip. I took it in to the dealer to get it looked at for this and a couple other reasons. They called and said that the oil cooler is plugging up which is restricting air flow to the egr cooler, causing the egr valve to soot up. The pickup is an 04 cc 4x4 with 76,0000 miles on it. Turns out I am 30 days out of my warranty coverage and they said it would cost $2,400. They have talked to ford about covering it and while we are waiting to hear, I thought I would ask the fte professionals if their explaination sounds reasonable and if they won't fix it under warranty, is there a better, more cost affective fix?
A plugged oil cooler will restrict coolant flow to the egr cooler. Then the egr cooler develops small leaks of coolant into your intake... this leaking coolant will gum up your egr valve making it stick. Check for white smoke when you first start it up and for several minutes after wards. Also pull out the egr valve and raise the rear of the truck and see if there is liquid (coolant) and/or sticky crud inside the intake.
 
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Old Nov 5, 2009 | 03:35 PM
  #3  
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janton01
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From: Pilesgrove NJ
Originally Posted by 2004SD
Thanks in advance for any help. My EGR valve has been sticking occasionally and this weekend while on a trip I finally unplugged it. The pickup ran great the rest of the trip. I took it in to the dealer to get it looked at for this and a couple other reasons. They called and said that the oil cooler is plugging up which is restricting air flow to the egr cooler, causing the egr valve to soot up. The pickup is an 04 cc 4x4 with 76,0000 miles on it. Turns out I am 30 days out of my warranty coverage and they said it would cost $2,400. They have talked to ford about covering it and while we are waiting to hear, I thought I would ask the fte professionals if their explaination sounds reasonable and if they won't fix it under warranty, is there a better, more cost affective fix?
Bought mine (04 larriat crew cab) with 85k in March. Started burping on a trip from Cape Hatteras to NJ. Turned out to be the oil cooler full of casting sand and not allowing much coolant flow to the egr cooler. No warrantee and cost about 2500 to have the oil and egr replaced. One other thing was that the engine drive fan ran all the time on the way back also. The egr cooler now has a ss plug closing it off so no exhaust flow into it. No more problems and engine runs very nicely. I also installed a coolant filter using the NAPA sysetm.
 
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