Hi. I have an 88 Ford Thunderchicken (5.0) that runs without the EGR and runs/hesitates/rough idle/shift issues with it plugged into the new 3) EGR components: the valve, the EGR position sensor, and the solenoid, which was not working. To my dismay, the 200.00 repairs made zero difference. My only solution was to disconnect "the saucer" and put a screw in the hose. Car runs great with it, but the temps are a little hot, not to mention I live in So. Cal. When installing the new EGR I was careful to clean the throttle body ports out with long Qtips, carb cleaner, and a toothbrush. I was wondering if those nasty plastic vacuum lines that have at least three hose repairs in them are the culprit, as the attachment elbow at the throttle body is melted in place (D-ohhh!) But your sheet metal idea is just a simply great idea. Was entertaining a soda can, but it might melt. What kind of sheet metal, how thick, do you reccomend?Two other EGR ideas
Idea 1. Get two new EGR valve gaskets. Sandwich a piece of sheet metal between and re install the valve.. It will keep the computer happy and keep the hot air out of the intake. This is similar to an accepted EGR valve test method. You would not need the resistors or plug thingy.
Idea 2. If you take emissions stuff off, please carefully put it all in a tote and do not hack up the wiring - just in case you sell the car or do not like what the missing stuff does to the computer.