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This still sounds like an EGR system issue to me, which is controlled by a number of sensors. Were there any codes when they had the scanner hooked up? Are you sure the installed EGR valve is good. As I recall reading on here, there were some issues with valves manufactured last spring being bad. I doubt this anything to do with whatever soot is in your intake.
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2004 F-350 Lariat, Supercab 4X4 FX4, DRW
Dark Toreador Red/Silver, 6.0L, Torqueshift Auto, ESOF, 4.10 LS, Camper Package, Dual Alternators. Build Date 6-8-04, Eng 5-28-04, Lance 9.5 Ft Camper.
Past 2002 F-350 Lariat, Supercab 4X4, Toreador
Red, 7.3L, Auto, DRW, Fully Loaded.
Past 94.5 F-250 Lariat, Supercab 4X4, 5 spd 7.3L PSD.
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