OK, so the EGR valve in our 2005 took a dump last week. It would occasionally had a constant high pitched squeal and the EGR code. (P0401, I think) Replaced the valve then like a real man, I took that sucker apart. The security Torx split the motor half from the valve half and in between is an hour glass shaped drive mechanism with a plastic coupler in between the two halfs. That coupler had fallen apart so it wouldn't open the valve all the way resulting in a low EGR flow code.
It makes me wonder how many EGR valves have failed due to this coupler failing.
There is a gasket in there but it's just protecting the drive parts from the elements and putting a bit of ultra black on the gasket would seal things up just fine.
But sourcing the drive coupler could be a bit problematic. My thought would be to have one printed on a 3D printer, but I don't know if those things can make a reliable part for this situation.
I will look into this further.
BTW, I did a bit of searching and found a PDF of some collected EGR discussions and I skimmed through that and the only thing I found was not to take it apart.
It makes me wonder how many EGR valves have failed due to this coupler failing.
There is a gasket in there but it's just protecting the drive parts from the elements and putting a bit of ultra black on the gasket would seal things up just fine.
But sourcing the drive coupler could be a bit problematic. My thought would be to have one printed on a 3D printer, but I don't know if those things can make a reliable part for this situation.
I will look into this further.
BTW, I did a bit of searching and found a PDF of some collected EGR discussions and I skimmed through that and the only thing I found was not to take it apart.