Its a 4.6, 4x4, 5 speed...The pipe coming off the driverside manifold rotted off...What are my options...The EGR valve went bad a long time ago and its been unhooked for some time...Worth just junking the whole system and blocking it off or fixing everything...

 

You will need an EGR hooked up and working if you want to pass emissions, if your state is like most others. I just put and EGR on my '02 and it was around $50. Should be $50-$75 for the tube... from the dealer of course.
Don't you have a real bad exhaust leak from the tube being rotted?

 

Just for an FYI; there is much more to it than just taking hardware off.
You can do that if you ignor the rest of the results.
1. you will have permant codes set that won't go away.
2. gas mileage suffers a bit.
3. there 'might' be ping at times under load.
All these actions are computer controlled in the program and 'may' be active at times unless the program inhibits them. The program normally substitutes fixed values until the system is operational again but codes still remain..
Normally what happens when the EGR is called to operate, the igniton timing goes advanced, and the fuel is cut back as the EGR opens.
These action are all transparent to the driver unless there is a fault.
If you don't have emissions inspection, your good to go.
Good luck.

 

Same thing happened to mine, I had to put headers and a new egr tube on. I had mine blocked off for a while but it ran ****ty and would cut off sometimes after interstate driving.

 

We have had the EGR valve disconnected for about 6 years, it only runs like crap when we reconnect it, other then that I am getting about 15-16 MPG on the freeway at around 70-80, the only time it would throw the check engine light is when we hooked it up...And when I picked the truck up after it being wrecked I found that the tube had finally rotted off causing a massive leak...We don't have emissions testing in Florida...

 

you can have the EGR delete adjusted for in the tune

 

??? What tuner??? I am lost...

 

I think you mean "who". Which tuner

 

Yea, a tuner has to EGR delete for yuh.

Here's a brief and a few 4.6L/5.4L parts -

http://rjminjectiontech.com/?p=9

There really isn't a need to do this, -it won't enhance performance and can (as Bluegrass points out) hurt economy.

 

It runs like crap when connected because you have a bad valve. If you do not have a CEL when disconnected, - well, someone had to modify the chip/program.

 

Nope...All my brother did was disconnect it back in 04...Never had a tuner on it...

 

Sorry, I don't believe it lol.

 

I know it dosen't get the mileage it should, it should be close to 20 on the highway, but other then that...it has been a good truck...

1 set of spark plugs in the truck in the 150K miles we've owned it (200K total), this was after we had to heli-coil the cylinder heads 3 times to put the blown out spark plugs back in, and we never pulled the heads off the truck either, just paid ford 169 bucks a piece to do it, completely rebuilt the front suspension at 170K miles, put a slave cylinder in it, put new spider gears, bearings, and seals in the rear and put 2 u-joints in the rear driveshaft...I think I changed the oil three or four times during that time also...

 

Heli coils ? - You have more problems coming lol. I've never heard of a Heli-coil lasting more than 2 years, -driven normally (miles). They just don't last. Time-serts are easy and a permanent fix for blowouts. Now you know

Just don't be surprised when a Heli-coil goes on yuh, - happens all the time.

Close to 20 mpg ? I thought you had a V8 ? Well, 20 mpg would be out standing in the 4.2L.

 

where's the BS flag