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I realize this is an old thread but I thought I'd follow up with it. The EGR cooler ruptured a couple days after starting this thread. I ended up sending this Ex to the dealer due to lack of time to dig into it. Of course they pulled codes and condemmed the turbo, EGR valve, EGR cooler, oil...

You reminded me that when I did the EBS, I also cleaned the EGR when the problem went away for awhile. I'd forgotten about that. I'll give it another shot. I'll delete it here one of these days.

Little more info. I've done the jiggle test on the harness running around the back corner of the motor. I've never gotten it to act up this way so I'm really thinking (or hoping) it's not a harness problem. Back when I changed the ICP there were codes for the EBP, turbo overboost, turbo...

It's tough to hear but the video in this thread sounds just like my Ex when it acts up. I had found another thread with another video that match my symptoms exactly in my searches on this problem but can't seem to find it now...

04' Excursion. Bone stock. The throttle surges at random in any condition. Hot, cold, in gear, in park, cruising, accelerating, etc. Sometimes dies while coasting or stopped in gear. When it acts up, the idle gets choppy or "crispy". Sort of like it has a big cam. You can be cruising and feel...