NOTE: This is a plastic body sensor with an improved design for lower failure rate. It is the correct replacement for earlier aluminum body sensors as well as later plastic ones.
We have personally owned several Ford vehicles, including a Taurus, a Sable, and a Focus that the DPFE sensor failed on. Usually the failure starts with an almost imperceptible surge while cruising. Gradually it develops into an annoying surge and then the check engine light comes on eventually. Checking the code will usually reveal that you have a P0402. Other codes that may appear include P0401, P1400, and P1401. This problem was so bad for a few years that Ford actually put out a bulletin saying that if you had any of these codes and symptoms, don't even do any diagnosis, just replace the sensor!
The following is a short description of how a DPFE sensor works:
When OBD2 was introduced, the EPA said that we now have to be able to know if the EGR valve quits working and turn the check engine light on if it does. Ford chose to do this by installing a slight restriction in the tube that brings exhaust to the EGR valve. Now we all know from science class that when there is flow through an orifice, there is a pressure drop across it. So Ford installed a pressure sensor across the orifice - when there is flow because the EGR valve opened, the pressure sensor senses the flow and tells the PCM the system is working. That's why they call it a Differential Pressure Feedback EGR Sensor! Now, what do you think happens when you run hot exhaust gas into a little electronic sensor? It does not last too long - and that is why you are reading this!
Anybody can install it - no rocket science required! If you own a Ford with the DPFE it will probably fail - sooner or later - buy it for a spare! Compare at around $130 at most parts store - for an aftermarket part!
