Engine Misfire Due to Plugged EGR Orifice on Ford Freestar

On higher mileage vehicles, one or more EGR orifice in the intake manifold may plug with sludge. This can cause the engine to misfire when first accelerating because too much exhaust gas is directed into the cylinders where the orifice is not plugged. Cleaning the clogged passages should correct this concern.

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Average mileage: 110,137 (46,000–150,000)
4 model years affected: 2004, 2005, 2006, 2007
29 people reported this problem
13 people shared problem details
2004 Ford Freestar120,000
My Freestar has been sputtering off and on when I try to accelerate, sometimes stalling out on me. It can go days without doing it, then do it all day long for a few days. So far, we have tried changing the fuel filter, and other things my husband thought it may be. We will be checking the EGR Orifice, seeing if it is plugged up.
2006 Ford Freestar126,000
Mis-fires - We get error codes that say cylinder 1 and 3 are misfiring (P0301 and P0303) We also just got code P0352-Ign coil B primary Secondary CKTR - Have not researched that yet.
my 2006 Ford Freestar the check engine light will flash the codes tell me that the EGR valve is bad and is missing number 6. put in new spark plug number 6 didn't do any good.will replace the EGR valve to see that fixes the problem.
2005 Ford Freestar128,000
with ac on a miss upon acceleration. with ac off, smooth acceleration
Misfiring ....engine light blinking
2006 Ford Freestar46,000
egr valve plugged with sludge , spray fuel injection cleaner , and added lucas gas treatment
2004 Ford Freestar143,000
engine miss fires at cold startup for a few seconds then it's ok. It is worse in the winter. Changed plugs and wires and coil still the same
Engine starts but will not idle.
2005 Ford Freestar150,000
When accelerate high speed sputter, had transmission flush stills sputters or skips
2004 Ford Freestar113,562
I am having the same problem, the van is misfiring and P0303 & P0316 are codes that keep going off. Going to check the EGR Value and EGR Orifice to see if this is the issue that will correct these problems.
Ford Freestar miss is at cold startup for a few seconds but if the miss goes for little longer like 20 seconds. Then light comes on but will go away after about 15 miles
Diagnosis p0106,p2006,p0300,p0305,p0306,p0316,p0174,p0171,p0401,p2197,p2195,p1000,p2006. It does not start in freezing temperature. It idles so fast that I dont have to put my foot on the accelerator for atleast a full city block. It runs rough, stalls at stop lights.
2005 Ford Freestar85,000
did not pass smog check. Ford dealer charged 506.00 to replace egr valve
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I have changed the plugs, wires and coil and the van still runs horrible. when you are accelerating it runs very slugish and has a miss to it. once you get up to speed it runs pretty good at consta...
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The wires, spark plugs and coil have all been replaced and the cylinder is still not working....
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Brand new coil still miss firing

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