EGR Valve removal tool - Diesel Forum -
6.0L Power Stroke Engine and Drivetrain Discussion of the 6.0L Power Stroke diesel engine and drivetrain in the 2003-Up Super Duties and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 6.0L Power Stroke engine.

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post #1 of 8 (permalink) Old 04-16-2008, 05:53 PM Thread Starter
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EGR Valve removal tool

Help! I'm removing my EGR valve to clean it out and change the gaskets, do I need a special puller to remove it, or what?

2005 CC Dually LB 6.0 PSD,
142k, FX4, IH HCFM, Fumoto, 5W40 Syn
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post #2 of 8 (permalink) Old 04-16-2008, 06:07 PM
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As these little buggers can get caked up with soot pretty good, I think a good tool is a ladies slipper, heal bar, etc., etc. You need to apply a fairly constant and upward force, working your way around the base of the valve body, to get it out.

'04 Excursion EB, 6.0 PS, 4X4, Magnaflow Performance exhaust, Isspro gauges (boost, pyro and tranny), Bilsteins, aFe intake, front and rear leaf spring upgrade w/ bags, 30mm rear sway bar, SCT Xcal2, Red-Head box, Jordan brake controller, Arctic Fox 29V - 20,420# GCW, Everything haulin' me, the wife, the 5 Amigos, Millie and Yogi (our 2 Berners).
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post #3 of 8 (permalink) Old 04-16-2008, 06:11 PM
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They do make a special puller to remove the EGR valve, but I have used a good broom stick with wire wrapped through the holes in the EGR Valve many times to pull mine. Just tie the wire, and use the broom handle to 'pry' up to pop out the EGR valve. It's kinda tough, but it should 'pop' out.

Good Luck!!

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post #4 of 8 (permalink) Old 04-16-2008, 07:01 PM
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Clean it - Use Carb cleaner, not brake cleaner - keep the fluid out of the weep holes. Use new O-Rings (kit number is 3C3Z-9P455-AB).

ALSO: Clean EBP tube (vehicles built before 9/23/03 have the EBP sensor taken out of the computer control strategy), Also clean MAP sensor hose and manifold opening.

If you have a problem getting the valve out, take the 2 8mm bolts out, spin the valve by hand, and use two lady fingers or heel bars depending where you live (1 under each tab) and pull it right out.

When you go to install the valve it is normal for the valve not to go all the way in. Push it as far as you can and use the bolts to suck it in (do it as evenly as possible).

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post #5 of 8 (permalink) Old 04-16-2008, 07:31 PM
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I used mechanics wire through the bolt holes steady upward pressure and tapped it lightly as I pulled, it popped right out. I thought about useing a pry bar of sorts but did not want to chance to much pressure on one side and cracking it.

2004 F350 xl super duty C/C long box 4x4 auto 6.0 ltr. airraid filter 4" magnaflow turbo back system, zoodad 209000 kms.

Past truck 1992 F250 XLT 7.3 IDI ex-cab 4x4 auto 372,000 kms. It ran great; then a moose killed it!
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post #6 of 8 (permalink) Old 04-16-2008, 09:04 PM
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Down..yes, there's a special puller for egr valve & suggestions made for removing without it. Main forum pg. at top.."6L FAQ" with pic's. Good luck!

03 F250 XLT SC/SB 4X4 6L (stock) TqS. SRW 3.73's BD:02/11/03. 01 TL 23' SGII
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post #7 of 8 (permalink) Old 04-17-2008, 09:18 PM Thread Starter
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Thanks alot guys, you really helped me out. I don't have shoe horns, but I do have a painters multitool, and that worked great when a pried it under the ears with side of tool from cleaning off a paint roller. Also a tip for anyone with kids that saved the small baby food jars, that fits the EGR just perfectly when letting it sit in Carb cleaner to prevent it from getting in the weep holes


2005 CC Dually LB 6.0 PSD,
142k, FX4, IH HCFM, Fumoto, 5W40 Syn
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post #8 of 8 (permalink) Old 04-18-2008, 08:22 AM
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Here are the EGR cleaning instructions from Ford Doctors website.
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