Ford 6.0L Powerstroke: EGR Valve Cleaning Procedure P0401 P0402 P0404 

I can't find anything stronger than 'Thank You So Much!' to express my gratitude! Thank You So Much!

Extremely helpful. My 06 is all stock and well maintained, hit 191,000 the other night and all of a sudden had major power loss and rolling coal like these idiots who hate their injectors. I envisioned head gaskets, EGR, oil cooler, everything. But simple cleaning and back in business, thank you.

Of the 8 EGR cleaning videos,you are the only one that actually cleaned the seat and stem correctly! I'm going to try oven cleaner with your method. Thanks!

Very informational and precise, I picked up a new EGR today and will tackle this in -0 degree weather, so hopefull y it goes quickly. I have searched the web with the truck's issue and this is what I am hoping it is. Black smoke, no power and dies every 5 miles. Thank-you again!

Thank you Ron we need more people like you in this world your videos have been a big help durning this overhaul

great way to clean the egr... I like how professional job you make.

Gotta agree with most everyone. Thanks. I found your video helpfull. My check engine light was on. I've never cleaned mine and got my truck new in 07. mine was horrible but thanks to your soaking idea. I got it shinny as a penny. truck runs great again. I will clean it more often since it isn't too hard of a job.

Appreciated. Cleaned just like you show, no more black smoke. Texas.

FYI great video...for all you DIYS'ers let me add to this video. If you do not have the cleaner as in this great vid..I am sure if you drive a F series you will have this laying around. ...."Hoppe's # 9 Gun Cleaning solvent " I scraped all the gunk off and then used the Hoppe's....spray it on a paper plate then roll Q-tips in the solvent....it will NOT hurt the gaskets but it will melt the black stuff off like ice on a tin roof. Almost effortless. Tooth brush if its heavy. Take a paper towel when done and wipe off/ dry off any excess. I have been using this for years...."carb" cleaner...Carbon cleaner carbon gunk crap. Its awesome.

Thank you so much for sharing your knowledge. I watched your video and tried to emulate your actions and it worked! My EGR valve was bad...just like the video. I could be imagining it but after cleaning the EGR valve it feels like I have more power.

Makuloco, thank you for all your videos! They are a great help and very informative, Good luck wishes with BSG Auto my friend!

I REALLY like your videos. I learn a lot from them. Some of the jobs I watch you do, I've already done myself, but you showed tricks that would have made it lot easier. I hope you don't mind if I point out one point of suggestion. There are a number of videos with very clean and clear close ups, but I think it'd help if you took a moment videoing from a father point and bringing the camera close so we could be familiar for where to look for these things. I mean, I know it's on the intake, but I think it'd make more of your videos clearer for some of us. Thanks!

Great video - it's worth cleaning and taking the time to do a good job they to buy a brand new one which is costly .

Thanks for doing more diesel stuff that is awesome!

Excellent quality video and thorough explanation!

I'm 6ft and 240lbs and I had to basically build a scaffold equal in height to the hood and lie on top of the motor of my 2003 F-350 6.0 thinking of how it's mostly plastic and still could not get my face over the the opening where the valve mounts in the cooler.. Am I missing something here?

Great video and explanation of what to do. Thanks for making it.

My 2003 F350 6.0 showed code for EGR stuck. It was moist and oily. My question is why did my truck not show ANY symptoms? No rough idle, no stalling or hesitation, and NO SMOKING from tailpipe.

excellent video. I will try it today. My 07 6.0 f350 starts for 1 second blows black smoke and dies. EGR code comes up with scanner.

Best think about my old Aerostar 4.0 it doesn't have an EGR valve to mess with. Still gets 26 mpg on the highway too!

Thanks for the amazon Link. It still works !

The shear filth of that was impressive. But when you said it wasn't that bad I just couldn't imagine what the you've seen is

What a guy. Excellent video and SUPER helpful

GREAT ILLUSTRATION BUDDY VERY GOOD

Ya really good tip. Just bought a 6.0 f550

Do you have to wait until the codes show up, or can you do this procedure before that, for preventative maintenance?

I got the po401 insufficient flow. I replaced the egr valve, didn’t fix it. What do I try next? It’s not smoking and generally runs good except for being a little cold blooded at start up. But it’s always been that way. Suggestion anyone? Thanks in advance.

I was getting this code after I did my head gaskets pulled the egr valve and found a pinecone stuck in it lol not kidding

my truck doesn't need much of what you post in your videos. but I'll be damned if I don't do it anyway. lol. I saw your hit side hose video. I'm doing that first. thanks so much

PLEASE HEEEEEEEELP!!!! I’m having the exact same problem. Swapped turbos, replaced egr, leaned the nipple on the Intake, changed the hose to the MAP sensor, replaced the MAP sensor, replaced air cleaner, and I STILL get -2.1 psi boost at idle and around 5.0 psi on the freeway. Now sporadically after engine is hot I can get a laaaazy 12-14psi under about 75-85% throttle, but not for long, and the boost goes up and down fluctuating under a load between 11-14psi during that time. Under light acceleration on the street the truck pulls smooth. When the boost show low or sub zero engine idle is rough. When boost shows 2.7-3.5 psi at idle engine idles great and pulls off great will lay you back in the seat. But that only happens when the EGR is either freshly cleaned or when it’s first replaced. Then after 5-10 minutes that dream goes away. Ficm main power shows a steady 47.5-48.0 volts. The sync monitor on the scan gauge shows 1 indicating crank and cam sensors are working properly, I changed the fuel filters, and the oil yesterday now running STP 15w40, ICP SHOWS 583 at idle and as much as 3700 under acceleration getting on freeway or a hard pull, IPR occasionally shows 73.3 but rare. I have seen high 60’s frequently. Guys I’ve done about everything I could think of or know of…..what’s next EBP tube and sensor ??? I’m starting a new turbo build with a 10 blade balanced assembly from KC. VGT vanes have always been in the back of my mind and has never really left. That prompted the turbo build. I often wonder if a plugged cat could potentially create such a problem as well. I need all the pointers and advice I can get. Has anyone dealt with this type issue before? This truck is all stock except for the air cleaner which came with the swapped turbo. I haven’t tuned or changed anything else from factory parameters or specs. I noticed there are no rubber grommets on the FICM. I’m wondering if vibration over the years could have had its effect on the FICM? Everything is pretty much original on this truck 2005 Excursion 6.0 with 186,000 miles. Up til this happened all she ever asked me for was a HPOP and an alternator. This has been the most dependable 6.0 ever. Just under friggin powered and I can’t figure it out!!!! Also note….after changing the EGR valve no more P0401 just still under booster and underpowered with black smoke under load (pulling) HEEEEEEEELP!!!! 😂😂😂😂😂

Can cleaning the EGR fix a p0405 or is that damaged internals?

Good info for us who aren't familiar with diesels. About how often would one expect to see this problem?

Great videos, I just had my head studs done about 2000 miles ago. Just recently noticed loosing boost and discovered the gasket ( not the O-rings) on the EGR valve was broken and the bolts were only finger tight. cpould that cause low end turbo loss? Thanks a bunch

This was great man! Thank you.

good info as a lot of techs on RU-vid give great info on diagnostics and repair. my question is, do these dealerships get mad about the info that is given on here because the dealer I work for Has fired techs for working on vehicles on personal time.

Awesome video, great explanation step by step.

Thanks for all the how-to videos!

excellent video and great way you explained it

If your gaskets are good they will slide or glide around the egrV effortless....if they are really hard, will not spin and your fingernail will not put a dent in them...u need new ones. They will be a litle hard but just as long as they spin they are fine.

Great video and thanks for sharing. Btw, your minimal effort is as much as my maximum effort! lol I have no patience.

Excellent video! THANK YOU.

It seems like you know a lot about these engines I have a 2006 F3 50 with the power stroke 6.0 and everything’s fine but when I go to turn it off it won’t shut off it’s like it’s staying started I have to pull the fuse out to kill it any help thanks

Is the Ford carb cleaner a pressurized spray or a liquid you pour from a container? Looking to do this this weekend and want to cover all my bases! Thanks bud!

You could just buy and Oriellys replacement valve that blow break into 3 pieces. Seen it happen twice. Ps if you pull your valve out and its completely clean you need a new EGR cooler because its cracked and the Coolant cleaned the valve for you.

Have you heard of a P0488 that doesn't have that part anymore?

Great video! On the port before you cleaned it looked like there was orange o-rings in there.. is that just part of the ones on the egr stem ? Or do they have their own that go down there.. just want to double check since I’m doing it right now and my kit only had orings for the stem

Very nice..thanks for the video..I use to this on my mustangs idle air valve.

Good video

Can you do a egr delete with the cab on ? Even changing the up pipe

I'm having a problem. Starting my 6.0 and it's making a weird noise out of the fuel pump but the fuel pump works and the smaller filter in the engine is getting fuel but not starting

My egr valve was sticking and I used contact cleaner on it and it melted the carbon off like butter in a microwave.

Is there more we can do to clean...? I have one I am fighting that keeps throwing P0401. Last about 3 days, then pop goes the check engine light.

Wow! You're amazing!

Het ziet er allemaal interessant uit maar ik versta geen Engels. Kan je Nederlandse afbeeldingen toevoegen maar wel van een Ford escort 18 TD

How often should the valve be cleaned?

About a 3/8s chunk of one my o rings was missing when I pull the egr. I'm wondering what I should do?

Also, after just pulling my codes, I have a p0401 & p0403 code. could these both be from a dirty/bad valve? like g previously stated, I'm doing the cleaning this weekend, but if that doesn't work, I'm thinking maybe I'll save to replace the valve completely. Your thoughts would really be great. Thank you!

What would cause rpm drop at idle on a 6.0

I know this is an old video. I’m just curious as my egr valve is wet/sticky on the top part. My cac tubes had oil in them and my turbo too. Is it possible oil could be bypassing the inter cooler and clogging up the top part of my egr?

HELP did this but top half separated from bottom part still in motor any tool o can get to get the bottom of valve out?

So is it worth it to bypass the EGR on the 6.0 or does it cause issues

I cleaned my egr valve and replaced it now it won't start. What should I do? Any help would be greatly appreciated

hey thanks great video just wondering I work on ic school bus's they have a 365 eng same as a ford 6.0 litre iam getting a code that reads high exhaust back pressure check the tube by the left exhaust manifold seems clear just wondering your thoughts if the egr valve might be the problem the bus kind of chugs around 90 km an hour I was just about to check the exhaust system for bent or plug muffler have not taken that apart yet thanks

What cleaning products did you use in the cup?

Will this cause make my turbo spool up slowly at the starting line? mine smokes like hell all black no tune.

I have a shutter at over drive speed going up hill. Any advise? Powerstroke 6.0 2006 f350 70000 miles

I know this sound stupid . But do I have to clean it aswell even if I have egr Delete?

Hi I have a slight problem with mine. when I went to remove mine the top part down to the ears for the bolts is the only part that came off the actual valve assembly was stuck in the manifold and would not come out. I cleaned what and put it back on the truck it still functions so it didn't break from that but any ideas on how I can get the valve out of the manifold because I don't trust it now and would like to replace it after that because i'm not to sure its supposed to come off like that and feel it might fail lol

Very well made! ❤

Thank you! Wow...

Could it be a p1335 code as well ?

So if you find these egr marbles then are saying that the egr cooler needs to be replaced?

So how often do you have to replace the EGR valve after you clean it. I noticed that it was a brand new EGR valve you installed not the one you cleaned out.

Thank you!

My2006 f350 make ugly noyse is come from the intake but my ingene runs good,I chek evretig no check ingene ligth,and I loose but the noyse I need help please

I found some moisture in mine and the bottom of my egr

Very good video!

I removed my egr valve to clean but I didnt even think about cleaning the inside out like this.

Ah, 120 # torque???, Did I hear that right?? Great job thank you so much!!!!!!!!

Gracias...

Mhm I can’t find mine.. oh wait 😏 I’m deleted

thanks man it was really usefull

Very Helpful

Would the 0401 cause a shake or shudder when hitting accelerator from a stop?

So you ended up just replacing the egr on that truck?.

This is one great video!! Very nicely done... thank you

Good job!

Slide of hand very sneaky

Do you know anything about the Dodge 3.0 sprinter motor. EGR Valve, Swirl valve & swirl valve actuators? I have a 2008. 55k mileage van. That is throwing the comes for the swirl valves. I've read you can completely remove them then put in some kind of electronic device that says they are opting & closing? Do you know anything about this motor??

Can I use liquid non-chlorinated brake cleaner for soaking the EGR Valve or does it have to be Carb Cleaner?

What is the cost of this doing it yourself? Also would you recommend an egr delete? Thanks.

Great vid

Hi mi 6.0 2006 lose power any idea

i'm chasing a p0303 code on my expedition with an occasional lean bank one code. I've changed the plug and swapped the coil and injector for other cylinders but the code still remains the same. some forums are saying the egr ports get plugged up and for some reason its able to push past into the #3 so it's getting all of the exhaust gas that was meant for all the cylinders on that side. They say the cure is I think to take it apart and clean the ports to all the cylinders. does that sound plausible? it's mostly when the engine is cold. typically once it's warmed up it runs great and the misfire is almost not even noticeable.

Good morning-- Does the EGR valve need to be cleaned if I have an EGR cooler delete?

What is in the measuring cup to clean the valve.

Pipe cleaner would work great with this.

What if u did a delete and put a straight pipe intake one I did that it’s came out a code later on if not enough flow?

where do you get that cat claw?

if i have a EGR block off on my 2003 6.0 is my EGR valve even used.. should i clean it?