I have cleaned the EGR ports in the throttle body, replaced the EGR valve, replaced the DPFE, and replaced the IAC, but no joy. The sputter is better, the idle is better, but it is still showing signs of sputter when accelerating and when pressing the throttle at any speed. I feels like something is choking the truck when accelerating. very frustrating and not very safe when pulling out in traffic. any suggestions would be very helpful.

 

Check the fuel pressure and the cats. low fuel pressure or clogged cats will cause your symptoms. No check engine light? I'd borrow a fuel gauge the pressure should be aroung 40 psi but I'm not positive. Then having the cats checked would be next..

 

What is sputtering?
A misfire,, no?
Why not address the ignition system?
If you have no codes for anything else the ignition is as good a bet as anything.
Get a Scanner and look at mode 6 test 53 the misfire counts for all cylinders and service for those that are high.
You done enough work and spent enough and not fixed the problem that you could have bought a good Scanner to diagnose with.
Just a different take to help.
Good luck.

 

Yup, when's the last time the plugs were changed? Motorcraft factory spark plugs are notorious for breaking half way down the plug inside the porcelain. Check the wires for arching. The older the more noticable. I had a 99 Ranger that had arching so bad that at night you could see the electricity shoot down the wires.

 

The 97-03 plugs are a standard one piece plug and should not break. The breakage issue was with the 04-08 model years with the two piece plug. On the 97-03 use motorcraft plugs, torque to 28ft.lbs., no anti-seize.

 

Not that break lol. What I mean is if the plugs are neglected for too long they can rust and break. My old 99 when I got it had 2 plugs that broke in half inside the porcelain.

 

That is very far from being a "common" problem with these engines. I've done plugs in several 2v mod motors and never had an issue getting them out.
From the information the OP put out there I stick with a flow problem Exhaust restriction fuel flow issue or it could possibly be a clogged air filter

 

*UPDATE* I took it to my mechanic and they advised me to replace my plugs and wires... believe it or not, there were 175,000 miles on the original plugs and wires. needless to say, after 250 for labor for 3 hours, the problem was fixed.

 

175,000 miles on the original plugs! OMG!