Ford Superduty Navistar Diesel EGR Systems and Problems?

D

Dave

New member
Is anyone Else having intake manifolds plugging up with carbon due to the EGR systems they are using from 04 to 07 on 6 & 6.4 Navistar Ford Diesels? As long as it is under the 80,000 km warranty period for emissions Ford keeps cleaning it. But once out of warranty period they give you two options to clean it. Removal and manually clean at 1250.00 or use a machine to clean it at 1100.00. This is all due to the inferior EGR system not being able to create enough heat to do its job. Causing it to carbon and plug the intake manifold. Has anyone else experienced this problem? Ford dealer told me it was my fuel cetane. However I fill at a fuel depot and it is Sunoco Gold at 45 cetane. So fuel is not the cause. If I have to do this twice a year at 1250.00 that is 2,500.00 more maintenance a year ??? Anyone else having this issue ? Thanks
 
Are you running an aggressive tune by either piggyback chip or a downloader? If you are, run a more mild tune, run more boost, or keep your foot out of it when the turbo isn't spooled (change driving habits).

Are you idleing the truck for prolonged periods of time? Stop & go driving?

One thing you can do is install the EGR cooler from an '03 6.0L on the '04 and later models. The '03 EGR cooler has round tubes; the '04+ have square tubes and are more prone to clogging.

As for the EGR valve sticking... You must replace or clean the valve.

Luckily I haven't ever had to clean mine on my '04. One thing I have on my side is that the truck is used 90% of the time pulling near max GCWR, so my exhaust temps are high and keeping everything burned out. This is why I asked about a performance tuner of some sort or driving habits. It the motor never gets hot or worked hard, or your dumping a bunch of fuel in the motor, your going to have more buildup.

Remember, smoke is wasted fuel...
 
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