Just installed a new EGR and gasket and its caked after three weeks, gonna just warranty a new one but how do I prevent this?

 

When you changed out the EGR valve, did you clean the EGR supply pipe? It can get caked up with soot from years of use and can foul up a brand new valve pretty quickly. I like to run a long pipe cleaner down through the supply pipe then start the engine without the egr valve installed and a plug in the port leading into the intake path. It is pretty amazing how much crap can come flying out of there!

If you did clean it, then it is possible that your engine is either running rich or not completely burning the fuel for some reason. Do you have access to a scan tool? If so, what are your fuel trims? Have you looked at your spark plugs? How does the engine seem to be running?

 

Engines been running great, changed the plugs when I did the valve. and yes I cleaned it but didn't do the trick with running it, ill have to try that.

 

Also, it's a 94 so no scan. Picked up a gasket with a screen on it hopefully it helps.