I'm thinking about making the switch from Cummins to Powerstroke, my 99 CTD is rides rougher then the ex, smokes grey to much and wanders all over looking to kiss everybody she's next too. Been looking around the site and there a lot of discussion about the EGR valve on the Powerstrokes. Having hte cummins, I figured out it has issues too, but I can't find out what the heck a EGR valve is, what it does and please, oh please it's got to be cheaper then replacing the injector pump the the 24 valve....right? easier too....right? Any help, from anyone? Thanks in advance

 

EGR is exhaust gas recirculation but I have no Ford experience to share dude........good luck man

 

Follow this link for more information about the EGR valve delete. Or you can just pull it every 10K or so and clean it out. It only takes about 15 minutes to clean and reinstall. If you run an SCT you can have your tuner turn it off.

EGR Block-Off Kit - Off Road Trucks - Diesel Power Magazine

 

The Fords seem to run a little better with the EGR functioning. I clean mine every 25,000 miles. It takes about 30 mins. total to remove, clean and replace. Not a hard job. Mine plugged once with about 30,000 miles on it. No damage or anything, the truck just wouldn't pull as well as it usually did.

 

Depending on what year ford your going with, the new 6.4 with a nice intake like banks or s&b and the tuner from sct with the dpf delete pipe is the way to go. They run awesome, and the fuel milage is bumped up to another 3 to 5 miles more per gallon. The stock egr sensor will plug into the new dpf delete pipe and the sct tuner is set up to run the correct program for this set up... Thats if you have to get rid of the cummins...

 

surf this site you will ba an expert on EGR valve in no time

 

The EGR valve is not a big deal. I clean mine every couple of oil changes and while I there
I clean the IAT2 sensor (intake air temp). Half hour at most. Use MAF cleaner so you
don't take the coating off of the sensor.

The big deal is the fricken EGR cooler. Seems like they are made of left over chinese lead
based paint (now that they can't use it on childrens toys, Ford gets a great deal).
The forums are full of folks with leaking EGR coolers and they are a pain to change ($,$$$).

Also seems that Ford is not real excited about warrenty claims.

The biggy is Ford used cheap head bolts and if you push too much boost the heads will
float off the block. This causes fluid leaks and head gasket problems.

That being said, I love my '06 6.0 !! No problems yet !

Haven't heard anything bad about the 6.4 yet. It too new and Ford is replacing it with a
6.7 in 2010 or '11. Makes me wonder why you would drop an engine when it's only been
out for 1 year....... (Ford said something about Navstar and want to make their own)

 

Your right on the money about the week head bolts, the other problem that I've seen is that when driven in a snow storm big or little causes the intake to get clogged. I have a customer that pulls sleds up to wisco every year and last year was stuck on the side of the road 3 times with his shiny new truck pulling snow out of the intake. Ford has no explanation for this but only to run a pre filter wrap or bag. I dont feel that if you spend 45000 plus on a truck that you should have to do this.