How To: Replace the EGR Valve on the 5.7 Hemi (P0406)
This was performed on a 2005 Dodge Ram 1500 QC 4X4 with the 5.7L Hemi.
I imagine it is the same for any truck with a Hemi but I can't say for certain.
CHECKING THE ERROR CODE:
My check engine light came on at 62,000 miles. I used the following steps to check the code and determine what the problem was.
1. Insert the key into the ignition.
2. Turn the key from OFF to the ON position (just before the start position) and back to the OFF position 3 times as rapidly as possible.
3. On the third switch to the ON position leave the key in the ON position. The odometer will then flash any codes the computer is giving.
In this case my odometer showed P0406.
I then went to Google, looked up the code and found it was the code for a bad EGR Valve. There are many ways to deal with a bad EGR valve found on Google, some say to clean it, some say to replace it. I had to do both.
TO REMOVE THE AIRBOX:
First remove the negative battery cable with a 10mm socket with extension and set it aside so it is not touching any metal part of the truck.
The EGR valve is located on the left side (facing the front of the truck) of the engine block just after the spark plugs and looks like this.
I found it much easier to get to the valve after removing the airbox.
Remove the cover of the airbox by unsnapping the clips on the outer edges. Be careful to hold on to the clips. They are designed to stay attached to the lower half of the box but two of mine popped out and fell down into the engine bay which led to a fun search to locate them and but them back on the box.
Once the top is removed use a screwdriver to hold it out of the way.
Once the top of the airbox is out of the way you can remove the lower half of the airbox by simply pulling up on the box. There are no screws or clips attaching the lower half of the box to the truck, just rubber grommets on four plastic posts.
Now that the airbox is out of the way you will have a much clearer view of the EGR Valve along with much better access.
2006 Ram 2500 5.9 Cummins Mega Cab 4X4 G56
5" TBE, Hide Away Goosneck Hitch, Leveled, Moto Metal Wheels, 35" Dick Cepeks, Laramie Front Bumper, Bakflip Tonneau Cover, Painted Heads, Tinted Tails, Painted Interior, Limo Tint, VP Secondary Fuel Filter. To Come: H&S Mini Maxx, Line-X Bed Liner, In dash DVD, Leather Seats.
Gone but not forgotten:
2005 Ram 1500 5.7 Hemi Quad Cab 4X4 SLT.
Leveled, 285/65/20 BFG All Terrain KO's, Bilstein BE5-6140-T5 Front Shocks, Bilstein BE5-6248-H5 Rear Shocks, Bakflip Tonneau Cover, K&N Filter, Debadged, 20% tint over factory in the rear, 15% on front windows, 5% stripe, Custom Y-pipe.
Last edited by aarondb4; 12-19-2010 at 02:34 PM.