EGR sludge, exhaust fumes

[Corsica3100]

I have a 3100 with the digital EGR valve. The EGR valve is clogged with sludge and the opening from the EGR into the plenum is filled with sludge. I took the EGR apart to clean it and the gaskets inside the EGR are brittle.
The EGR is realatively new, it's less than a year old. I have cleaned it once, but the sludge came back. To top it all off, when I turn the heater on, it vents exhaust fumes into the cabin. I think the fumes are leaking through the EGR gaskets. Where the heck is all this sludge coming from? EGR = PITA !!! Please help

[Doubt_Incarnate]

usually build up in an egr valve is dry, or hardley damp. if it is some kind of ooze than you may have a problem elswhere. like running rich, or a bad head gasket.