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1996 EGR Valve 5.0L

chuck1022

Member
Joined
November 23, 2022
Messages
33
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16
City, State
Scottsdale az
Year, Model & Trim Level
2000 ford explorer v8
Thank you all for helping me with my exhaust manifold issue. I successfully put a cast iron 97.5 manifold on my 96 and everything seems OK.

Now I would like to replace the EGR valve. I have P0401 CEL. EGR "A" Flow insufficient detected.

I will order a new EGR VALVE but the common theme is the impossible bottom bolt.

Would my life be easier taking off the throttle body elbow it is attached to?
 



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Test the valve first. That code is often thrown by a cracked vac line
 






It can be easier to remove the whole
Elbow yes however it is possible to get those egr bolts if you have the right combo of tools

I would do an inspection first make sure it’s not something simple

 






Copy... I will start with simple.
 






I use a shorty ratchet wrench to get to it. It's not in the greatest spot, but it's not too bad
 






What is this thing next to EGR

20230322_101326.jpg 20230322_101340.jpg 20230322_101400.jpg
 


















Yes that is the vacuum switch that controls vacuum flow to the diaphram
 






So that could be f'd up and not the actual EGR?
 






Or the vacuum lines to it

Simple check if you apply vacuum to the diaphram it will open you can see it move

When the one on my 96 went bad I could clearly see a rip in the orange diaphragm membrane
 






Mine was bad and causing an excessive EGR code.
 






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This would work right???
 






yes that will apply vacuum for testing
can also use your mouth for a quick test
 






Thank you all for helping me with my exhaust manifold issue. I successfully put a cast iron 97.5 manifold on my 96 and everything seems OK.

Now I would like to replace the EGR valve. I have P0401 CEL. EGR "A" Flow insufficient detected.

I will order a new EGR VALVE but the common theme is the impossible bottom bolt.

Would my life be easier taking off the throttle body elbow it is attached to?
I'd like to suggest that if you're going to put in a new EGR valve, then replace the tube at the same time.
 






You may want to go ahead and replace the EGR Vacuum Solenoid, mine failed and burned out part of the Powertrain Control Module. You're driving a '96, it's due. Preventative maintenance. The solenoid has a coil in it activated by the PCM which moves a valve to regulate the vacuum to the EGR, the coil can wear through and short out the circuit to the PCM melting those connections in it.
 






Replaced vacuum solenoid. Check engine light still came on. Bought new egr valve,,,,it looks wrong to me???!!!

20230328_155549.jpg 20230328_155545.jpg
 






The one I posted pics of looks like it has an electronic connection to it. Maybe I take that off the old one and put it on the new one?
 






The EGR position sensor is attached to it. Just swap it to the new EGR
 



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