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Old 04-06-2008, 03:23 PM
Rob Rob is offline
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Ha Ha Ha i say!!!

so in response to stumps desription on how hard it is ( its a booger ) to remove the EGR Valve in the tech files, i say bull, i dont think its possible for the meer mortal man to get this out. it takes the Force of a Master Jedi to remve it cause i can not get it to come out. i fought with it for an hour and gave up.


EGR tech file
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Old 04-06-2008, 04:10 PM
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Hope this helps:

If you have a problem getting the valve out, take the 2 8mm bolts out, spin the valve by hand, and use two lady fingers or heel bars depending where you live (1 under each tab) and pop it right out.
When you go to install the valve it is normal for the valve not to go all the way in. Push it as far as you can and use the bolts to suck it in.

If you are going to clean it - Use Carb cleaner, not brake cleaner - keep the fluid out of the weep holes. Use new O-Rings (kit number is 3C3Z-9P455-AB).

ALSO: Clean EBP tube (vehicles built before 9/23/03 have the EBP sensor taken out of the computer control strategy), Also clean MAP sensor hose and manifold opening.
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Old 04-06-2008, 04:22 PM
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I agree it was a pain in the@#$%^ when I did mine. Bismic's description is a great one I had to spin mine and use heel bars to get it out. Mine had over 100k on it before I cleaned it.
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Old 04-06-2008, 04:43 PM
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I usually don't have much problem with the EGR valve but when I was at Scuffy's I couldn't get it to cooperate. He used a long pry bar from the driver's side and tapped it under the mounting ear then just pryed on it and popped it right out. He makes everything look extremely easy!
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Old 04-06-2008, 05:38 PM
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easiest way to do it,...try this next time.

#1...this is an electrical part...I have to advise to disconnect both batteries...no point in taking a chance with your electrical system.
#2...get one of these:



It's the worlds cheapest gear puller...they can be picked up at any Autozone, for under $10, and they are good to have around. Since most of us don't have access to the Ford puller...this will work...you just have to get creative with it.

Here's your target:



You can see the plug on the EGR...obviously, unplug that.
I also had to remove my boost gauge line.
I removed the plug that goes to the unused (in my truck) controller for the throttle plate thing. I just did this for easier access .

Remove the 2 screws from the ears on the bottom of the EGR valve.
Both mine were different...I don't know if thats the norm...but I made sure to put them back into the holes they came out of.

Now..rotate the EGR untill you can get the tabs on the puller onto the ears on the valve.
I had to use a pair of Channel Locks to do this.
Now put the puller in place...something like this:



Now is where I had to get creative. Since this is NOT the correct type of puller...you obviously do not tighten the center bolt...if you do that...you'll destroy the EGR and won't even get it out.
What I did was put a small prybar under the center of the puller and GENTLY pried it against the intake elbow. I put a folded up towel between the bar and the elbow for some cushion...you definetly don't want to break that elbow.

Anyway...I just put some pressure on it and it popped right out.
Nothing to it.

Now the nasty part.......here's what I found:



Gets kinda ugly in there huh?
Well...when you get it out...just go to town with a can or two of carb cleaner. I also used a small interior cleaning brush to get into the tight spots.
Once you get the crap out you can pull the valve itself out and clean the valve face and the seat. Actually, there are 2 valves and seats on one shaft....you'll see.
I guess the cleaning part is a no brainer...just clean till the black crap is gone.
After I got done...I had this left:



Once you have it looking like that...put it all back together.
Re-connect the batteries and you're done.
It takes about an hour to do.

Some things to note:
Be carefull...you don't wanna break this stuff....it's expensive....
There are 2 o-rings on the valve....be carefull not to nick or damage those.
You'll notice on the last pic...there is a gasket on the valve that seals it to the intake.....do not damage this. If you do...it won't seal right and hot, pressurized exhaust gasses will shoot out into your engine compartment.
Again..I am NOT a diesel tech...use this info for your own good and at your own risk.
Don't blame me if you break something.

Last edited by TANK'S 250; 04-06-2008 at 05:50 PM.
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Old 04-06-2008, 05:42 PM
Rob Rob is offline
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Well after 2 hours of bending over trying to get it out, i got it. i talked to scuffy and he gave me some ideas to try. they worked. it was filthy. looks new now!!! anyway, i would have cleaned the rest too but i dont have time. ill probably get to that stuff next week end. WHEW!!!!!
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