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Senior Member
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Discussion Starter #1
First off...this is my first attempt at a "how to" article...so bear with me if I ramble a bit.
Second...I am NOT a diesel tech. This is just how I did it and what worked for me...with some input from other members of this site.
Thanks to those who offered guidance to me....I'll pass that on now.

O.K. here I go.........

#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. 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....LOL
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.

Well...thats about it...I don't think I missed anything.
I hope I did'nt bore y'all too much.
 

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Obviously Intuitive !
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1,417 Posts
Well done UB !

I think this is a keeper :)

And I especially like the thought of using the "efficient with my money" tools !
 

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Registered
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218 Posts
Hey man that was a great how-to. Does it apply to the 7.3 also?
 

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Registered
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1,126 Posts
nope, yall are lucky....no egr
 

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756 Posts
:thanks: :Thumbup:
 

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Senior Member
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2,691 Posts
Great write up UB.This should be a sticky!
What did it look like down inside the engine where the EGR fits?
I have seen some pics with lots of crap in there
 

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Senior Member
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3,630 Posts
Discussion Starter #10
Lots of crap in there too...but I did this in my hotel parking lot.
I have a shop vac at home...I'll be pulling it again, along with the intake elbow so I can put the vac in there and use a wire brush to knock the stuff off and vaccuum it out at the same time.


BTW...Thanks Ford for such a well thought out system...... :poke: :barf: :thanks:
 

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hotel parking lot. classic
 

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Got Torque?
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This is a great thread for the many out there who need to clean their EGR valves. Nice work,

RL
 

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You can apply a little bit of lubricant to help those o-rings slide into place. I have used the red synthetic wheel bearing grease. Just a light coating.
 

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Discussion Starter #16
Honestly...I just do mine when it acts up.....the first time was when I took those pics and it's been done once since then.
 

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jet ski racer
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327 Posts
I just cleaned my valve tonight. I didn't getit as clean as what UB did. We will see if she runs any better. I used some long zip ties pushed through the ears on the valve to pull it up, worked great!
 

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Member
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81 Posts
If you don't have a puller,you can turn the EGR valve slightly and then use 2 ladies foot pry bars under the mounting ears and gently pry upwards evenly.The shop vac's with a 1 1/2" hose end will fit down into the EGR valve hole to vac out the loose carbon(recommended),you do not have to remove anything other than the EGR valve to vac out the carbon.
 

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Diesel Pro
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2,652 Posts
just did it today too, cause we did a 15-90 run today and got out and noticed coolant was everywhere, all over the frame, so we cleaned the egr first to see if that helps, cause its never been done in the 57k thats on it
 

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new o-ring kit is available from ford, dont get any cleaner inside housing as you will camage the windings and position sensor. ford tune up cleaner is recomended for cleaning,soak valve in tune up cleaner for 1/2 hour.
 
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