This is a basic explanation of the egr system on the ford ranger. This one in particular is from my 1997 4.0 liter. I had a p0401 code setting off my check engine light. I still might have to replace the dpfe sensor as well but this is how I cleaned the egr tube and removed and replaced the egr valve. I removed the fender well but that is only necessary to get at the bottom of the egr tube. All of the other components are easy to get to. To get my egr tube off i had to use pb blaster and a propane torch. it took awhile but it worked. Hope you guys find this helpful
5 mm socket
8 mm socket
10 mm socket
1 inch wrench
1 1/16 wrench
new egr valve and gasket (cost me 41.99)
pb blaster and carb cleaner
1. I put the driver's side front of my truck on a jack to give me more room to work. Remove the negative battery cable.
2. I removed the bolts that attach the plastic fender shirt from the fender well. Don't forget the plastic ones
3. now you have more room to work. move that stuff out of your way and don't loose them.
4. Next locate the egr valve, tube, dpfe sensor, and solenoid
5. Take your pb blaster and soak the nuts on the egr tube and bolts for the egr valve. Sometimes they can be welded on due to the heat. Reapply and use the torch as necessary to loosen them. the bottom two are easiest to get at from the fender well.
6. Once you have those loose i checked and removed the top tube on the egr valve and the egr valve bolts. careful because only one of the egr valve bolts has a nut on the end. Also there is a gasket that needs to come off from the egr vlave
7. Once you have the egr valve removed you can clean the tubes out if you don't want to remove them. i used carb cleaner as mine weren't really clogged but some people reccomend using pipe cleaners to really get in there. i guess a flexible bore cleaner for a rifle or something like that could work too
8. Double check all of your hoses and tubes running the system and make sure you don't have any cracks or breaks. It's easiest to get at them now.
9. Grab your new egr valve and gasket. I used antiseize on the threads just in case I have to remove the valve in the future to make it easier next time.
10. Place your new egr valve and gasket into position. Don't forget to tighten the tube and re-connect the top tube on the egr valve
11. Put you battery cable, wheel, and fender shirt back on.
If that doesn't resolve your problem here are some trouble shooting tips from my manual for the rest of the system.