Be sure you get new gaskets / o rings.

 

Okay, Thanks again. Oh yeah, GO COWBOYS!! Great game!

 

Even when you get a new one, you need to clean the intake area out as good as you cam. Shop vac to help sucking all the crud out as best you can. Why not try a good cleaning first? wouldn't hurt, and a little less expensive.

 

amdriven...

I was just thinking I forgot to mention that...


Oh.. after the cleaning is done... "Italian tuneup" to blow all the crud out of the engine.

If you all of a sudden, have nearly no power, most likely it is a piece of carbon jammed the intake / exhaust valve open.

Pull over, rev the engine a bit, and it should blow it clean.

Mine became nearly perfect after I really tuned it up --- 3,000+RPM, max throttle... many times.



As for doing the cleaning and reinstall --- well --- if you have the ability to test the EGR valve.. sure... I did that.. .and to my regret... discovered the valve is electrically faulty.

So being the cheapskate I am, I got a used valve, cleaned it... installed it.. and off I went.

But in the interest of time --- the new valve is something like $200? before discount at the dealer?

Let them dealer parts counter guys make some $$$

A good parts guy is worth their weight in gold to you.

 

I was told to replace the gasket and "O" rings even if I just clean it. Is this correct? Also, what is the prefered method of cleaning? Just scrape and wipe, solvet? I don't want to screw this up. It really started messing up after I was trying to pull some kids out of the mud during a rain storm and got stuck myself. lol wrong tires and 10" rain in 3 days don't mix. Anyway, I was reving my eng. really high and for quite a wile until I got out. That's how it all began.

 

Hope this page helps
Diesel Technician Society

 

My truck has been throwing the P0404 code. Pulled the EGR valve out and cleaned it, reinstalled with new gaskets. Still throws the same code. Seems to happen when I'm pulling my 40 ft 5th wheel up a steep grade. Also getting an occassions Jerk/miss/skip in the engine when pulling really hard. Could this be related to the EGR problem.

How would I tell if it is a bad EGR valve?, bad PFE sensor?.....or something else?

 

Replace the EGR valve with a new one and see what happens.

If you have Ford diagnostics equipment, you can bench test it.. but if you don't ... it is $200.


Did you clean the carbon from the plenum?

That is probably where the problem is.

 

Yes, I cleaned the Plenum, it was not that bad. Truck is a 2004, but only has 55K miles on it.

Any thoughts on the aggressive jerk when pulling hard? Related?

 

Howdy again. I'm stuck. I'm unsure if I'm doing this correctly. The egr is on top next to the alt. and has an electrical conection in the top. it is silver with a black plastic center. about 2 inches wide and 3 inches tall. It has two small mounting hex head screws. It will spin an inch or so until the screw ears it the block or other obsticals. It will not, however, pull out. I understand there are "O" rings that are creating a seal. WHAT DO I DO? Just put a "KUNG FU GRIP" on it? I tend to break stuff when I go too fast.

 

Howdy again. I'm stuck. I'm unsure if I'm doing this correctly. The egr is on top next to the alt. and has an electrical conection in the top. it is silver with a black plastic center. about 2 inches wide and 3 inches tall. It has two small mounting hex head screws. It will spin an inch or so until the screw ears it the block or other obsticals. It will not, however, pull out. I understand there are "O" rings that are creating a seal. WHAT DO I DO? Just put a "KUNG FU GRIP" on it? I tend to break stuff when I go too fast.

 

The approved way to pull it out is to use a coathanger to pull against the two "ears" and use a pipe to lift UP hard on the coathanger tied to the ears.

Somewhere on here, Mark has an excellent photo pictorial of how he did it... and of course... Mark is the pro at this job since he keeps his EGR and run perfect with it.

Trust us... it comes right out.

Clean the inside of the plenum as best as you can.

9 chance out of 10, you also freed up carbon particles that cannot be reached ---

So it will get into the intake / valves and you pray it doesn't jam the valves open.

If it does... use the method I outlined to clean the carbon out of the innards of the engine.

 

THANK YOU! Very nervous. I'm a carpenter, pumber and electrical handyman. good with my hands but never worked on a PS before. I'll let you know how it turns out.

 

Read this:

https://www.ford-trucks.com/forums/4...egr-valve.html

 

Thanks! It popped right out, just as you said it would! I never doubted you. lol Now I see by the pics that I did it right. Thanks again!