EGR valve STUCK! - Ford Powerstroke Diesel Forum
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post #1 of 33 Old 05-23-2008, 04:09 PM Thread Starter
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Angry EGR valve STUCK!

Hey everybody,
long time lurker, but now I need some help. This site is great and has helped me alot with fixing up my new truck. Ok truck is a 2003 6.0 with 133,000 miles on it. I blocked off the cooler with the freeze plug in the up pipe and have an sct on it so the egr is disabled. I have been trying to get the egr valve out to clean it or make it stay shut. I took bolts out and tried channel locks,I turned and wiggled for an hour with no luck. vice grips and prybar,nothing. I found posts here about the wire handle trick. I tried that with a prybar and kept breaking the wire. so i waited and found the crowsfeet pry bar, still wouldn't pop out. now totally fed up i found some stronger wire and a big pipe. all that did was bend the tabs up and still nothing. is there something really wrong here?
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post #2 of 33 Old 05-23-2008, 04:13 PM
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Taking off the intake makes the job much easier when the egr is going on or off... give it a try,

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post #3 of 33 Old 05-23-2008, 04:53 PM Thread Starter
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will that give me a straight shot at it to get something like a pickle fork in it?
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post #4 of 33 Old 05-23-2008, 06:02 PM
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It is prolly coked up pretty good. Be PATIENT and try two crows feet under tabs rocking back and forth. Turn tabs so that you can get under them with crows feet. They make a puller for removal but can be pricey.

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post #5 of 33 Old 05-23-2008, 08:16 PM
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+1, just keep at it, the first time I pulled my EGR, I worked at it for a good hour. The two o-rings lock it in pretty tight. The 90* prybar method worked well for me.

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post #6 of 33 Old 05-23-2008, 08:44 PM Thread Starter
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OK thanks guys. Ill have to get some more or different prybars and try some more. I've been driving with it unbolted today hoping it would heat up and pop out, even pried on it while it was hot. This thing is in there! Probably never taken out before. If I can't get it is there a way to tell if it is open, or will it even matter with the egr disabled.
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post #7 of 33 Old 05-23-2008, 09:06 PM
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HENCE why I don't want a 6.0 cause of the EGR... you poor guys, and poor Ford for just having to have them on there. Stupid emissions, eh?

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post #8 of 33 Old 05-23-2008, 10:19 PM
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When my EGR got stuck I just took it off and cleaned it and it worked like a charm. It's supposedly a "temp fix", but I did that about 8K miles ago and havent had any problems....its also cheaper than buying a new EGR.

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post #9 of 33 Old 05-26-2008, 09:56 PM
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Took my egr out today, I used a puller (like the one you would use to pull a pulley. Put the grab bars across from each other and remove the bolt in the center that is used to push the puller away from the shaft. Hold the hooks under the egr flange and GENTLY use the pry bar to lift up on the puller assembly. Mine popped right out, but take your time. Hope this helps.



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post #10 of 33 Old 05-27-2008, 05:01 PM Thread Starter
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Ok I worked on this all weekend and it's not coming out.I took the alternator and intake off and modified a puller very similar to the one Da Big One used. I had to get it comepletly under the valve cause it kept bending and the puller would slip off even with a hose clamp tightend around the arms. I wish I had video of this because it was so ridiculous. Anyways I asked a friend if I could take his off on an 05 too see if there was something that could've came apart and held it in there. His took 10 min with just the channel locks. So now I am hopping it is just so coked up that it is totally plugged so I don't have to worry about it and not somebody jb welded it in. Now the tabs are so messed up I can't even bolt it back down, not that it matters
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