96 Ex 4.0 EGR excessive flow code ... please help a.s.a.p.

[mccoyxx]

Hello & thank you for your time ... I have a 96 Ex 4.0 that popped a code about 4 days ago "EGR excessive flow" I replaced the EGR and DPFE about exactly a year ago and I don't know what else would throw this code. It was running fine, then today started missing terribly, then just quit and I cranked and cranked and it tried to start and would run at approx. 500 rpms and then die after a few seconds ... it was making a backfiring sound inside the intake ? and sputtering really bad when it finally did start ... and it wouldn't rev above 1,000 rpms with the pedal to the floor ... any suggestions are greatly appreciated ... RSM

 

[mccoyxx]

I forgot to mention ... I already changed the coil pack and it didn't help at all and it has a brand new fuel pump from NAPA that was installed approx. 5 days ago ... so its getting fire & fuel ... I can't imagine how an EGR sensor could cause such a problem.

 

[mccoyxx]

ok , so I went out last night and changed the EGR and it done nothing ... its running super rich and now its idling a little high and then dropping almost to stalling then jumping back up again ... however when I give it gas it stalls and won't rev up at all ... I checked the tubes going to the DPFE and they are good and the tube to the EGR isn't clogged. Any suggestions from here ? I replaced the DPFE approx. a year ago, but NAPA and the dealer are saying that could be the problem. So I have one on the way now ... if that doesn't work could it be the EGR solenoid/relay thing that the EGR top tube/hose connects to ? what about an IAC ? any suggestions are greatly appreciated ... thank u again for you're time ... RSM

 

[jremington59]

I don't think the egr issue is causing the vehicle not to run. New fuel pump or not I'd probably have a pressure test done to make sure there's no problem there.

Are there any other codes?

 

[swetrid]

If egr is stuck open it could cause your symptoms.

 

[mccoyxx]

thats the only code coming up ... put new DPFE on today and nothing, took to a garage and had a snap on scanner hooked up ... no codes except it said ARC fault ? auto ride control? dunno ... anyhow no misfire all injectors tested fine, fuel pump tested 100% ... took TPS and checked to make sure it wasn't weak/stripped inside ... all ok there ... even the mechanic is anot sure ... going back tom. and have a fuel pres. test ran ... it did however say the EGR was closed the whole time the test was ran even under a load driving it never showed it open ? whats the odds of both EGRs I have doing the same thing ?? could it be the solenoid for the EGR ?? thanks for your time I need my Ex up and going I feel naked without it !! I drove my friends tracker today and if felt like going from shooting a 9mm to a 22 LOL !! ... RSM

 

[jremington59]

Are you saying there was no longer an egr code?

 

[mccoyxx]

No ... the EGR excessive flow code remains .... the snap on diagnoses tons of info on almost everything you can think of and the mechanic went through it all and the only thing he found with anything wrong was it said ARC on the diagnostic and then it said fault beside it ... other than that everything checked out ok .... everything was well within good running specs all injectors good, no misfires, fuel pump @ 100% , throttle response working properly, maf good etc. ... thats what we don't understand literally everything is checking out good ... I believe perhaps ARC ... thats automatic ride control ... and my model doesn't have it and thats why its popping a fault ? other than that I am literally lost as to what could be going on ... thank u again for your time everyone ... RSM

 

[mccoyxx]

Listen to this !! found the problem

Ok , so I finally after replacing every EGR component on it and putting the new fuel pump on and still not changing a thing broke down and took it to a garage ... you ready for this ? it was a split o ring that goes on the fuel pump assembly ... they almost never found the problem either ... and ready for this ?? it gets even better ... even though you can replace all of the pieces on the assembly and the pump itself inside ... literally no one sells this small rubber o ring/gasket ... not even Ford Motor ... now I ask why would they sell all other things for the fuel tank except this ??? anyways ... they somehow cobbled me one together out of a spark plug boot and it was hard to start all day the first day and wouldn't start the 2nd ... I took it back and the rubber swelled and split and popped out. So they made another invention yesterday from plastic and a piece of gas line and its running better than it ever has since I have owned it ... literally starts in 1-2 cranks everytime now !! wish me luck that it holds up and thanks for the replies ... RSM