How can I tell if I need a new EGR valve? I haven't installed once since I've owned it. I tried to remove it once to inspect it but was unable to get it out.
If you aren't getting codes, it is probably OK.
Here is a trick for popping that valve out of there.
Remove the two small bolts holding in place. Firmly grasp the EGR valve and twist it so that the tabs are accessible. Use a good length of tie wire (2-3 feet long) and feed one end of the tie-wire through one hole in a tab and the other end oif the tie-wire through the other hole. Twist the tie-wire ends upon themselves, forming a loop above the valve. Using a rake or shovel or broom, insert the handle through the loop and use the alternator for leverage. It will pop right out of the intake.
for directions on how to clean it.
Do I need to do a coolant flush if I did one about a year ago and already have a coolant filter in place? If I'm removing the two culprits that usually are clogged would there be any other areas that the "goo" could be lingering? What coolants do you recommend?
If you are running the Ford Gold coolant, absolutely. Especially if you have not been maintaining that coolant by checking the nitrite level every 15,000 miles and flushing the cooling system every 45,000 miles.
I have attached the FORD TSB for Diesel Coolant Maintenance that you should read. It details how you are supposed to maintain it, which not many do.
Your oil cooler has become plugged by the junk that forms due to neglect of the Ford Gold Coolant. Coolant filters will help, but it will not cure the problem.
Flush it out of your engine and be rid of that beast.
I went to the local International Truck dealership and bought the coolant they use (Fleetrite ELC). NAPA also sells a Zerex ELC that meets the CAT EC-1 designation. Make sure the coolant you use meets that designation, and not all of the ELC's out there do. (ELC=Extended Life Coolant)
Below is the line I have so it's the older style cooler? It looks like it's in good condition so what are the benefits/advantages to buying a new line and a complete cooler housing? Do you know the part number for the new cover and would I just need to buy the cover and the cooler or is there a whole set available?
Yes, you have the oldest style line, and to be able to change the oil supply line would require a new oil cooler cover.
The issue with the "old" lines is that a slight restriction can form in the interior of the flexible stainless steel portion. I believe that the replacement covers are a little on the pricey side, but am not completely sure about that.
Give Tousley Ford a call and ask them for pricing.
They used to sell the oil cooler and the oil cooler cover together as a "kit" but I believe that kit has been discontinued.
The oil supply and drain lines would be separate purchases as well. These two lines will run you about 100 bucks.