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

A proper scan tool is needed for just about any 6.0L problem this is my recommendation-
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Ford EGR Valve Seal kit- 3C3Z-9P455-AB
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Best method to remove the EGR Valve from Intake-
• 6.0L Ford PowerStroke ...
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[@JohnSmith-ok9sn]

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

[@ricflair8357]

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.

[@levijones1874]

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

[@knatocommander7673]

Egr delete kit doesn’t require the egr valve right?

[@ericmendez5815]

🤫

[@luisudiaz6326]

Can't found mine do the truck function the same whit out ?

[@jettjensen4902]

Oh wait no one cares!

[@Omegazstar]

Why you here then? 😂

[@joeprimal2044]

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.

[@williammoore5277]

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?

[@crossxcats]

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

[@omp9665]

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

[@joeespinoza147]

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

[@jdgarwood66]

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.

[@wachnir9]

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

[@petemoss9693]

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 .

[@jameswalker8832]

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!!!! 😂😂😂😂😂

[@carterstirrett1383]

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

[@FordTechMakuloco]

Yes easily on a 6.0L

[@pablosalas9898]

How often should the valve be cleaned?

[@jdiazpdx]

I read on powerstroke hub; best is to do every other oil change, or atleast once a year.

[@michaeltorres9575]

GREAT ILLUSTRATION BUDDY VERY GOOD

[@brettwafford9069]

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

[@DENicholsAutoBravado]

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!

[@dave121968]

Excellent quality video and thorough explanation!

[@chrisduffy7519]

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!

[@fernandoherrera4287]

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.

[@466htrd]

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

[@ddd228]

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!

[@WizzRacing]

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!

[@kevinfixthewifi3881]

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

[@keepinglifesimple4974]

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

[@FordTechMakuloco]

John O'Meara On our engines anyway those sensors are notourious for going bad and setting codes. The ceramic disc in there fails over time for the acids in the exhaust.

[@keepinglifesimple4974]

tried cleaning the egr valve the other day and it seems to have fixed the problem where is this disc located on the valve thanks

[@SethHarr]

Thanks for doing more diesel stuff that is awesome!

[@twisterad3]

This was great man! Thank you.

[@ebehrman]

Awesome video, great explanation step by step.

[@Chato4570]

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

[@williammoore5277]

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.

[@dlynes]

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

[@dlynes]

ken towne if you said anything I cannot see it.

[@edwardthayer9386]

Pipe cleaner would work great with this.

[@careylee5951]

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

[@FordTechMakuloco]

+carey lee White or greyish marbles

[@careylee5951]

+FordTechMakuloco I cleaned out the solenoid. What I did notice was while it was running I had smoke coming out of the dipstick tube.After running for about ten min my boost at 3500rpm is maybe 10.

[@Aardvark49]

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

[@FordTechMakuloco]

Victor Sorlie Can happen in as little as 15-20k miles if the truck is used like a grocery getter.

[@donovanziesmer3682]

What would cause rpm drop at idle on a 6.0

[@petroczinationalrailservic10]

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?

[@famman100]

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

[@FordTechMakuloco]

Really that's interesting

[@davidhaley7053]

Good video

[@SGuirin]

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.

[@pauldudko6062]

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

[@yo6488]

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

[@norbertopineda321]

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

[@jfogle01]

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!

[@manukeairvine]

Wow! You're amazing!

[@tierneyalexander4146]

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

[@TennesseeBass849]

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

[@sonnybunny2305]

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

[@gahunteroutdoors]

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

[@manguydude287]

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

[@saintspawn7285]

Could it be a p1335 code as well ?

[@jfogle01]

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!

[@calimesacox]

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.

[@joequayzar4592]

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

[@FordTechMakuloco]

There are only o-rings on the egr valve side.

[@1silentwar]

@@FordTechMakulocoI noticed that too I was worried they might have melted or something.

[@jbaz964]

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

[@bencross8573]

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

[@memoochoa392]

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

[@dieseltech1981]

good info as a lot of techs on KZbin 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.

[@donaldhoughtby9002]

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

[@jdgarwood66]

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.

[@DWATSON1975]

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?

[@estevanatkinson2993]

What a guy. Excellent video and SUPER helpful

[@lurch1924]

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.

[@FordTechMakuloco]

+Lurch 352 Ford has us replacing them now.

[@lurch1924]

Oh ok that's good to know. I do have another ? though. I've got a 2006 f350 dually it has a hard start when cold but then a long crank when hot sometimes doesn't start. When I read the live data the low oil pressure rises slowly once it hits 250psi it'll start. What are your thoughts. Thanks

[@MyBlowncobra]

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

[@TheLuigiTech]

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

[@ringodescamps2618]

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

[@ouimetco]

Ya really good tip. Just bought a 6.0 f550

[@stuartfreeman2620]

What happens when you replace the egr but the engine light is still on

[@TheBirdandEagle]

Excellent video! THANK YOU.

[@rocsvt1]

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

[@TheBalance2024]

Thanks for the amazon Link. It still works !

[@andrewdeberry479]

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.

[@MyBlowncobra]

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

[@nmattcar]

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

[@FordTechMakuloco]

Yeah this guy was a Farmer and needed his truck back asap. The EGR valve was available, but the seal kit would be noon next day. With the Fall Harvest going on he chose the faster option.

[@nmattcar]

That's what I figured.this time of year is the busy money making time

[@riverking4u]

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

[@FordTechMakuloco]

I clearly stated 120 inch lbs not foot lbs.

[@urielvazquez5129]

What cleaning products did you use in the cup?

[@grt8guy03]

excellent video and great way you explained it

[@SN1PE]

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

[@FordTechMakuloco]

no

[@allejandro50]

Hi mi 6.0 2006 lose power any idea

[@ltsgarage7780]

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??

[@FordTechMakuloco]

No sorry.

[@ltsgarage7780]

@@FordTechMakuloco do you know any u-tube sites that might? This is a highly common problem.

[@briankidwell232]

Slide of hand very sneaky

[@Dawnta12971]

What is in the measuring cup to clean the valve.

[@FordTechMakuloco]

Dawnta Napper Ford carb cleaner.

[@Dawnta12971]

Thank you, I need to clean the Egr passage now. I still get Service Engine Soon light I have a 2001 Buick Lesabre code P1401.

[@MoparMadness93]

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.

[@JDM797]

Thank you! Wow...

[@blosom2315]

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.

[@FordTechMakuloco]

I wouldn't even mess around I would do intake gaskets on this first thing then retest.

[@blosom2315]

cool, thanks

[@dauraktv]

Very well made! ❤

[@عباسالكربلائي-ث6ت]

ممكن مترج عربي

[@hddm3]

where do you get that cat claw?

[@FordTechMakuloco]

The one in the video is a Husky brand at Home Depot, I use it for everything.

[@hddm3]

ok ya I see you use it all the time. real handy. thanks

[@Tanker3278]

Thanks for all the how-to videos!

[@diyaromar9850]

thanks man it was really usefull

[@basandrew]

Great vid

[@waynewilliams1922]

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

[@FordTechMakuloco]

Wayne Williams Can't be more than $15. An EGR delete is a good idea in general yes but illegal.

[@waynewilliams1922]

FordTechMakuloco thanks for the quick reply. Just bought a f250 today and it already had the delete. I love these trucks now even more.

[@TileRoofsCanada]

Very good video!

[@rubenrodriguezmartinez5594]

Gracias...

[@y.g6947]

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?

[@FordTechMakuloco]

EGR delete needs to be programmed.

[@y.g6947]

FordTechMakuloco it has a banks chip came with the banks intake box but when I switched it to a straight pipe intake it started coming up random am gonna put the banks back and wait for my sct x4 programmer

[@jasonw9431]

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

[@FordTechMakuloco]

No the egr valve will be detuned out of the calibration.

[@jasonw9431]

@@FordTechMakuloco thank you 👍🏻

[@cocoo6760]

Very Helpful

[@JamesTyreeII]

Thank you!

[@pfrealestategroup823]

Jeez dude, buy new EGR valve

[@steveroe532]

New EGR valve from FORD is about $360.00, seems that a $10.00 kit and a little time might be worth the effort.

[@SuperLukedukem]

How do I contact you if I have questions on my 6.0

[@FordTechMakuloco]

Facebook messenger is the best place.

[@SuperLukedukem]

FordTechMakuloco : I don’t have Facebook.

[@jamout65]

Good job!