New to me truck, 2006 6.0. Was getting an intermittent P0404 code which means the EGR valve isn't responding properly. Only happened during high load situations, generally if I would put the pedal all the way to the floor, otherwise would not come up. I was able to get the EGR Command % and the EGR feedback % on the Scangauge so I could watch the valve operate in realtime. Pretty much followed the command. When cold the valve showed 0% as commanded.

Pulled the valve, it was fairly dirty. Cleaned it and reinstalled. Still got the P0404 during high load situations.

Decided to buy a new Ford EGR valve, which ended up being a reman. New valve will not go below 7% when the PCM is commanding 0%. Does not throw a check engine light and the valve will start working once the engine warms up and the PCM starts commanding it to open (around 160ECT if I'm following the temp correctly). Except sometimes the valve will get stuck closed at 0% when I start it up and throw a P1335 (minimum stop error). This usually happens after I stop for gas on a long trip and the truck doesn't have much time to cool down before being restarted. I drove it for an hour waiting to see if the valve would open and it was stuck at 0%. Parked the truck and when I got back to the truck after a few hours, the valve started working again. But would still only go down to 7%.

Sounds like I need to get the new valve replaced under warranty, but I wanted to double check if this is something common?

Thanks,

 

Does it need lubrication?

 

Never thought of that but some lube on the valve couldn't hurt and then reinstalling.

 

With all the carbon that flows through there some o ring lube couldn’t hurt. Some engine oil on the valve stem would be ok too.

 

Don't want to hijack your thread, Dave, but I have a used spare EGR valve I was planning to just swap in, then make my known working one the spare. In reading your issue, I'm wondering if we can test the EGR valves before installing? Is it as easy as supplying 12V to it? Would rather not install a valve to find out it is bad after the fact...
Scott

 

I have an EGR valve you can have for shipping too. No need for it!

 

PM sent...

 

I pulled the valve last night. It seems to move fine and appears to close all the way. Not really much to lube on these valves, and I've always been told to never spray anything liquid up into the "motor" housing.

Put back in the old one and it goes down to 0% just fine. I'll see if I can get this one replaced from Tousley...