Rough Idle Caused By EGR Sensor Sticking on Ford Excursion

Intermittent rough idle may be caused by the EGR sensor sticking, causing the EGR valve to stay slightly open. Our technicians tell us the valve and sensor must be replaced together to correct this concern.

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Average mileage: 138,500 (93,000–210,000)
Exhaust & Emissions affected: 5.4L V8
6 model years affected: 2000, 2001, 2002, 2003, more2004, 2005
11 people reported this problem
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Viewing 1 - 3 of 3 problem details
rough take off,battery light goes on, and altenator shows it's charging ok,and battery is good. now my engine light is on all the time, with rough idle.
2004 Ford Excursion 93,000 mi,
Pull wire plug off egr valve. remove two bolts that hold it in. remove egr valve with "crows foot (Tool" Grab with crows foot on edge of egr valve. Pry slowly. Be carful not to damage both o-rings. Clean all carbon off valve. Start engine and spray good carb cleaner or spray brake clean in egr valve hole and hold gas peddle at 2500 -3000 rpm, until exhaust is clean (one can). put some high temp grease on o-rings and replace. This will help for about a year. I Haven't decided what I am going to do next
I have owned my 2005 Ford Excursion Limited Edition (Diesel 6.0L) truck since 11/2006 with one prior owner. Although it has a little over 100,000 miles, it has constantly been in the shop due to a sticky EGR valve sticking. I have paid a large sum of money to my Ford Dealership and is constantly told "this should fix the problem once and for all." Well, it's in the shop again for the same problem....I have seen other Ford Truck drivers on side the road with black smoke coming from the all too familiar site. Called Ford regarding a recall that I noted on the internet site ( and found where a recall was issued in July 2005. (Ford Recall # 05S34) After inquiring with a Ford representative...well wouldn't you know such recall has ever exsisted. That figures, just made me realize its time to get rid of it....and never buy any Ford products again. I have owned several Ford vehicles in the past and husband drives one also F350. I will never buy another vehicle made from this company AGAIN!!!!!