You cannot make any change/take apart the EGR system without getting a CEL lamp and a code. It's designed that way to detect anything that happens or is done to defeat it.
Put it back togather and clear the code.
Your miss/stumble is not the EGR system.
You have one or more bad coils that are marginal. There are only two major parts to the ignition system outside the PCM. The plugs and coils.
It's probably a lean miss that you are not recognizing as such. This dosn't often set a code or a lamp because it's not a 'hard' fault but a 'soft' one..
Lean is those times that the PCM program runs the motor toward the lean side for fuel and is not a fault unto it'self but if there is a marginal problem with the ignition, stumble comes and goes with the lean running periods.
A coil with shorted turns in it's winding may still work at reduced output voltage but may fail under the short term lean conditions because a lean mix is harder to fire and exceeds the voltage needed and available from the faulty coils.

 

I finally got the job done. I replaced all 8 COPs and plugs. The COPs from Global and the plugs are Motocraft sp479's. MY MISSFIRE AND STUMBLE OFF THE LINE ARE GONE !!!!. The truck just seems to run smoother down the road and when I back out of the garage it is smother as well. Many thanks to those that helped diagnose this and find me the cops on Global. BTW, number 8 is a pain in the butt. Had to pull the fuel rail to get at it.

By the way...number 8 was wasted. You can see the carbon tracking on the boot.

 

Congrats

next project will be easier for ya!
how long did it take

 

Took 3.5 hours. BTW, don't miss any o-rings when putting the fuel rail back on... that fuel pump can dump a lot of fuel in no time at all. :mad

 

it's always the little details that get you
i just try to pay close attention when i take it apart.
i've always done farm mechanics.
reference material is not always available

 

Not me,still having problem at speeds between 35 and 45mph.it chokes out when it goes into over drive.
I changed all 8 cops and plugs took out mass air sensor and sprayed clean,throttle body als.New fuel filter,bought aK&n air filter next is to clean injectors.
Other than that truck runs super strong with a good idol,where else can I check.
Thank's

 

[QUOTE=*hammer]Not me,still having problem at speeds between 35 and 45mph.it chokes out when it goes into over drive.
I changed all 8 cops and plugs took out mass air sensor and sprayed clean,throttle body als.New fuel filter,bought aK&n air filter next is to clean injectors.
Other than that truck runs super strong with a good idol,where else can I check.
Thank's

You have a bad COP in the bunch - it's not very common- but that's whatcha got..

Try to force a check engine light by giving it hell as soon as it starts missing to pinpoint the cylinder.

Your looking for a blinking check engine light - it will blink a few time and then stop and go away. When this occures , you have a code set and need to get it read.

Once read - change that cop with one of you others and send that one back to Kevin - he will send you another..

 

I remember doing that back in the day, jeez, when you do it 20 times, coil packs and plugs can be done in 45 minutes lol, and removing the gas tank 5-8 times you can do it in under 10 minutes.... That is nothing to be proud of, everything takes for ever to do!

 

The sh^t does take forever sometimes - I just added a cat - that's all I had to do and it took half the freakin night to do it right. You can always cut corners when doing stuff - But DON'T !! It will haunt yuh - then you'll be doing it again anyway..

 

Thank's I was hoping that was not going to be the problem but I have no choice unless I take it to ford and pay them to find out the problem.I never heard of this before,this truck runs so strong at all speeds great startup and she idles perfect you can't feel the truck is even on.
Is there any other part I can check before I try finding a bad COP,if a mass air sensor does go bad what are the syptoms.
Is there a tool or machine that can simulate my truck at 45mph in over drive and find out where the problem is. Thank's

 

A scan tool with the capability to read Mode 6 data will be able to tell you which cylinder is suffering the misfire. Just look at the individual misfirecount PIDs.

Sounds like you have a slightly weak COP. a bum plug, or you're bleeding spark.

Steve

 

Appreciate the help,I was just about to buy a brand new mass air sensor,I will take it to auto zone.
If I did have a bad mass air sensor what would the syptoms be.
Thanks again

 

A Malfunction Indicator Lamp (MIL) would be blinding yuh if it was bad.

Those usually just get dirty and need to be cleaned regularly. When there really dirty they can produce a light.

I don't think I have ever seen them go bad - If one of those little wires inside the MAF break - THEN it's bad , that usually caused by foolish mortal error.. But , again - you would have a MIL on.


If you think you have MAF problems - Clean it and check the wires inside . Check the connector as well.


What happening to make you think it's a MAF problem?

 

I was just wondering if I had a bad one,you told me to change the cop's and I did and spark plugs too.
I took out the maf and sprayed that down real good.I still have that choked out surge at 40-50mph that driving me crazy so I'm going to take it to a mechanic.Thanks

 

[QUOTE=jbrew]
Hey jbrew. You say that he can give it hell to pinpoint the cylinder when it starts missing, and then have the CEL flash, and then read the code to pinpoint the cylinder. Just out of curiousity, why is all the advice around here to replace all 8 COPs at one time if you can pinpoint which one is the problem?

Not asking to be sarcastic at all. Looking for information. I too have a shudder, especially around 45-50 mph, and even more so when towing. I am likely going to replace all 8 COPs since there is 114k miles on it and I am not sure they've been done before, but it would kinda be nice to pinpoint which one is really jumpy right now to begin with, just so I can examine the plug and COP on that cylinder closely. That way, I'll know what to look for in the future.

BTW, you are an unbelievable wealth of info on here!!!