'05 4.7 code 0404 -- EGR acting up?

Hi folks. New to the forum here. I recently bought an '05 Dakota 4x4 with 4.7

I have been going through it fixing things, refreshing things, replacing things. It is getting close to being a good solid reliable runabout now but there are still a couple of things left bothering me. This may be a bit long intro background - however I am giving to you exactly as it is from day one. Here is a short list of what hast been done wrt the engine. (other mech stuff I am leaving out as this is an engine section)



- the truck had been sitting for 12-16 months then I bought it.

- truck has 178k on it

- thorough engine bay cleaning. Mice had nested in the hood pad, in the air filter box, in the windshield cowling, and a nice one on top of the engine between the heads under the intake manifold.

- dropped and replaced all fluids, new air filter,

- new PCV, cleaned breathers

- new spark plugs, the old ones were burnt off - probably original.

- all wiring and plugs checked for damage, corrosion, tightness, etc.

- throttle body removed and cleaned up. Had just a light dried old oil film on it

- tank filled with fresh fuel and a bottle of fuel system/injector cleaner dumped in too

- the seller said the truck ran fine but was getting check engine light just before they parked it.



OK so that is what I've done, and here is what I am experiencing:

- On first couple of starts, the exhaust was clear but a bit smoky, white. Did not stink at all. Was typical clean water exhaust smell. This just may have been residual condensation in the exhaust system. At idle and parked on the pad it idled fine and revved fine.

- Next ... This was before the spark change and the PCV/breather cleanup. On the first couple of test drives the truck was REALLY sluggish. Idle was a bit rough. Stalled twice when throttled up/down a bit for stop/go/creep at stop lights. On the highway there seemed to be very little power difference between 1/4 throttle and 3/4 throttle. Had to floor it to get any response. Fuel economy REALLY sucked. Burnt half a tank to go 30 miles! Check engine light came on mid way in the test drive.

- Replaced the plugs, (after discovering stinky mouse nest under the intake), had it all apart so did the plugs. They were found pretty much with electrode burnt right back to the insulator tip.
- Replaced PCV and cleaned out the little holes in the breather tubes at the back of the valve covers.
- Cleared the check engine by disconnecting the battery.

- More test driving. Power and smoothness seemed to be getting better each time I took it out. Still stalled a couple times, but idling is alot smoother and is rare on the stall. Ran the tank down to 1/4. Check engine light came on. But only when I had come off of a stop and throttled back quickly. This time I hooked up my DiabloSport i1000 to read the code. Gave P0404. Cleared the code.

- Push a fresh fill of new fuel in and 1/2 bottle of seafoam. More test driving. Again power and smoothness seems to be getting better each time I take it out. The engine just sounds smoother now and feels snappier. Is getting more responsive on the highway now. Fuel economy is up, but still a dogsled. It is not yet acceptable for what I expect out of a V8 in a little truck. No stalls though! Same thing on every ride wrt the light. Check engine light comes on when getting off the throttle and slowing down. Typically after a short burst of throttle and chop. The code shows up as P0404 again.



My thoughts and approach to all of thus far has been that the truck was and is still suffering from sitting idle; old stale fuel and possibly some gumming up of the fuel system from that. I've been going along that line by burning it off and topping off with fresh fuel and a dose of cleaner or seafoam. I am hoping that this cleans it up and after 4 or 5 tanks it is where it should be.



I looked up the meaning of the P0404 code. It indicates an EGR position mismatch between what position it says it is at and what the PCM wants it to be at. I have inspected the EGR wiring and connection. All looks fine.



So after all that, I guess my question is whether there is anything that can or should be done about this P0404 EGR code or is it possibly just a matter of getting more runtime on the engine and maybe that EGR will clear or clean itself up?



I will not be totally happy until: 1. there is V8 power felt in the seat. 2. fuel economy runs in the 17-19 mpg range. 3. engine runs totally smooth all the time (like my Hemi). 4. no random fault codes like is happening.



Thoughts/comments?