Ford Excursion :: EGR Marbles - Truck Loses Pretty Much All Power Below 2000 RPM / Smokes And Stinks Bad
Feb 12, 2015
EGR marbles -- the chunks of carbon that come loose from the EGR cooler / intake manifold and stick the EGR valve open?
I've been getting these on 3 recent occasions, maybe 100 miles or so apart. The truck loses pretty much all power below 2000 rpm, smokes and stinks bad until I pull the EGR valve and dump these out. I'm trying to decide if I need to dig in and do a new EGR cooler and oil cooler. I've read the FordDoctorsDTS article suggesting these are caused by and coming from a leaking EGR cooler (possibly only when very hot) over time.
I'm not currently losing any coolant that I can tell, but was losing some a few months ago (during warmer weather), but also had a leaky heater valve that I replaced at the time. Not sure if the leaky valve would account for the total coolant loss (I lost over a gallon in a few weeks).
Here's the additional details:
- 2004 Excursion with just over 109K miles
- Replaced faulty EGR valve (was sticking open) about 300 miles ago
- Replaced stock turbo with new powermax turbo 300 miles ago. Old was rusty and pitted with sticking unison ring.
- I just did a total coolant flush, oil cooler back-flush, Restore and Restore+ and added new coolant filter
- Replaced thermostat during coolant flush. ECT stays pretty close to 190 degress when warmed up.
- ECT/EOT delta is mostly between 15 to 18 degrees, sometimes slightly lower or higher. Not much change after the coolant flush, but may be slightly improved.
- I've been doing pretty regular wide open throttle tests during recent test drives with the new parts above (I'm thinking this may have broken some of this stuff loose).
Here's today's marbles. They're all dry and will crumble if crushed. They are dull gray on the inside - not metallic as they kind of look here............
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So my 01 has been parked in the garage for about 2 months. Normally on battery tender but it accidentally got unplugged and I didn't realize til yesterday when I went to start it. So I got the battery charged up and put air in my rear drivers tire since every time it sits it goes flat. Well I did all this I so I could take it to get tires today.
Driving to work and its shaking pretty bad at highway speed. Don't recall it doing this yesterday. Never really did this before either. The truck also pulls hard to the right. Its done this for a while so I'm not sure if it's just the tires or needs alignment or something else. Or all of the above.
I'm mainly concerned with why it was shaking. The front tires don't look low however I will check the pressure on my lunch hour today.
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Approx. 20 miles later it starts again. This time I have to jump the battery. I ran the truck and it drove without issue. Again a couple weeks later it starts in again with the light flashing and electrical dying. What it may be? I'm probably going to get rid of the truck as I can;t justify to myself to keep dumping money into it.
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