Question about 2002 Ford Escape

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2001 Ford Escape EGR Valve Keeps Cracking

We have replaced this part 2 times in 2 weeks at $75 a pop. It just cracked again causing the car to shake when idling. We also had the exhaust fixed, a tune up and the carrier bearings repaired within the past two weeks.

What is the cause of the EGR continuously cracking now?

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  • missterious Sep 13, 2009

    It is actually not cracked, it keeps exploding from the inside out (like high pressure coming from somewhere). Any suggestions?

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Its the cloged right cloged catalytic convertor the egr vales pressure comes from ther when the cat is cloged,it looks for another pressure eixt point which there are only 2 though the muffler if not cloged then 2nd egr im going throug a rough time with this as well,because they are charging me over a thousand to replace the cat and only 1 they said you should do both sides which will cost another thou yep thats around 2 thou this car has 3 expensive beastor cats

Posted on Sep 22, 2009

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If it is cracking at the mounting bolts, it is almost surely an uneven mounting surface or improper torque on the mounting bolts. Check for old gasket material left behind under new gasket or burrs/damage to the mounting surface itself. It is machined and needs to be perfectly smooth. It should not require excessive tightening either. Snug with a regular combination wrench. I do not have the exact torque specifications without looking at the service manual. Sorry. If it is cracking elsewhere, get back to me. I will figure it out for you. I hate to hear of unnecessary repeat repairs. Good luck to you.

Posted on Sep 13, 2009

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For the pressure to be that excessive to explode as you describled is due to there being a blockage in your exhaust system. All it does is measure what he pressure in the exhaust system. It should not be that great that it is blowing it out. I blew mine out while trying to make it to the exhaust specialist to fit a new catalytic converter. The guy at the spare parts place said on BA falcons they used to use a plate to block the maifold end and put a ball bearing in the exhaust side to stop it every happen again. The replacement cost for an EGR valve is $200 at trade price. I am going to see if a mate can tig the hole which will leave the unit inoperable but fix the leak and see if the engine idles ok. If that doesn't work I will have to go spend that $200.

Posted on May 26, 2010

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1 Answer

My egr valve keeps cracking


What you should know is the EGR valve is an Extended Warranty part under Federal Pollution guidelines. While the mileage and age of your vehicle may have exceeded the Warranty period of the original Factory part, there are some guarantees on the replacement part depending on the brand.

That said, it is The EGR that is the victim rather than the cause of your problem. Overheating of the EGR is the likely cause of the cracking. The EGR is not apparently opening fully or at all.

This is a problem. Because the onboard computer should be monitoring the various switches that control the opening and closing of the EGR valve.

I would suggest having the passages to the EGR valve cleaned. Have the Vacuum lines to the EGR valve checked for routing between switches. Incorrect routing of the Vacuum lines can also cause poor acceleration.

Smoking, EGR valve failure, etc can be a clogged Exhaust system too!

Before buying another EGR see if you are eligible for a free replacement.

Have a compression test done to verify engine health and replace the sparkplugs at that time.

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Ok here is the solution when I had the exact same problem with my 2001 Ford Escape:
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