I was at Autozone while the tires were being rotated on the car and saw something in the HELP section that peaked my interest.

An EGR gasket with a screen over the port where the gasses come into the valve. It says on the back that it "should" block things that cause the EGR to get sticky and malfunction.

Merely putting it out for discussion. I'm not sure I believe a screen of that sizing would stop much from going through.

What was the screen like? I understand how an MAF screen can help keep things out of the engine, but a screen to the EGR valve where nothing would be passing through besides gas...I must not be understanding something.

However, you must look at what is traveling up in there...whenever ive had mine off of my cars..in the manifold itself, there is always black chunky dried flecks...id imagine that crap can travel right up into the egr and gum it up...?

Hmmmm, I think you got it I know I've taken the upper tube off, and it'* all black and sooty inside, but not chunky, just dust. The bottom one must be much worse.