1997 STX 4.0 EGR valve corroded

atbeall · #1 06-16-2011, 08:15 AM

Hello forum – this is my first post. I have a 1997 Ranger STX extended cab 4x4 with a 4.0L V6. My engine recently started running rough, and the check engine light came on. Borrowed a code reader, and pulled P0402 excessive EGR flow. Inspected the EGR valve, and it is seriously corroded! To the point where if I grabbed it with my hand and pulled, I think the top of the valve would rip right off. Not sure how/why it is corroded so bad? Valve obviously needs replaced, but it is so corroded I can’t even remove the bolts. I’ve sprayed with PB, used a wire brush & pick to get the loose stuff off, but am still stuck. Has anyone ever encountered this before? Any suggestions are greatly appreciated. She’s dead until I get this figured out!
Also, does anyone know if it’s possible to eliminate the EGR system from the engine altogether? Bear in mind that I am a weekend warrior with a big tool box and a Haynes Manual! Thanks for any help!

pooleo · #2 06-16-2011, 10:16 AM

I have a post in an EGR thread on here somewhere, it has pics on how to plug that thing, I'll see if I can find it

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well, I had no luck finding it, I searched all my "threads I posted in" so I'll guess I will just repost the pics

Alright, so basically you buy one of these. Then tear apart your egr from the motor. Plug the metal line with some high temp hose and shove a bolt in and clamp it. I put some black RTV around the plug so it would not come out. very easy fix.

atbeall · #3 06-16-2011, 12:54 PM

Thanks for the info. I will have to take a look under the hood when I get home to better understand what goes where. I see the EGR tube gets plugged with the hose/bolt/clamp combo, but not sure where the T-handle stopper goes? Also, how did you remove the tubes from the EGR valve - everything on mine has really bad rust.
If I go this route, do you know if it will continue to throw EGR codes? In OH we are required to get emissions testing every other year and they check OBD codes.
Sorry for so many questions, hope I don't sound too ignorant. I do appreciate the help!