Join Date: Sep 2009
Location: Cincinnati, Ohio
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If you have the EGR valve unplugged you may get a CEL (just FYI).
There are a number of way to do an EGR delete. If you are not worried about passing a visual emissions inspection in your state, I suggest completely eliminating the EGR cooler because that will eliminate future failure of the cooler. If the cooler is eliminated, you need to replace the up-pipe with a straight pipe. Most EGR Delete kits provide all the parts you need. I used the Sinister Diesel kit that I bought on Ebay.
When you removed your EGR valve, you saw the crud on the valve. That stuff is all through your intake manifold. It is possible to delete the EGR cooler without totally removing the intake manifold, but I recommend removing the manifold and cleaning it out. If you do this, you'll need new intake gaskets.
Depending on how many miles you have on the truck, you may want to replace the oil cooler while your at it. Most dealers replace the oil cooler when they replace a failed ERG cooler because it is often the source of the failure. Casting sand from the engine block can clog the coolant passages in the oil cooler. This restricts the coolant to the EGR cooler and causes it to overheat and fail.
Cincinnati, Ohio - 2005 F350 XL FX4, SRW, Crew Long bed. Glow-shift pillar gauges, By-pass oil filter, EGR Delete