Solved P0401 EGR Flow Insufficient Detected

[Number4]

My '04 with the 4.6l just threw this code. The DPFE is part of the EGR, which isn't cheap.

Anyone with the 4.6l solve this? Wondering if the ports are filled with crud and just need drilled out, or if it's usually the EGR itself.

Been experiencing high negative fuel trims (close to -10 that is) for some time. Not even sure off the two could be related. As well as eggy exhaust smell at times.

 

[Number4]

Replaced the EGR valve and the codes not come back. So glad Ford incorporated the cheap DPFE sensor into the expensive EGR valve in '04+.

 

[gtyates]

Just saw your post. Same gripe that you have. My sensor went bad, but had to replace the entire unit. Have you ever had to replace the rear wheel bearings? That is not a cheap repair due to the design.. But I will say my '04 now has 129k miles and still running and driving great. The stupid heater box in the dash as a broken door for the defroster (also a terrible design), but tight now that is the only item not working properly. Fortunately the defrost door is stuck open, so at least my son can clear the windows.

 

[Number4]

All four bearings
All four shocks
Both front upper control arms
Timing
Alternator
EGR
Lower radiator hose to block gasket
Front and rear sway bar bushings
Needs left front axel shaft input seal replaced

Fresh air/recirc. and defrost flaps busted. I rig the defrost for winter and to the front vents during summer. Just removed flap completely for fresh/recirc.

I must be missing a few things. Purchased with 130k, timing went at 150k, now has 197k.

Has survived an incident with a deer that saw a new hood, fender and bumper. Which introduced me to the wrecking yard.
This in turn gave all black leather interior (third row seating, second row cap. chairs from an '06 Mounty,) back-up sensors from an Aviator and an electric fan....which died.

 

[Number4]

Interesting enough, having replaced the EGR assembly, I went from getting 135 miles per first half of tank to 152 miles per first half.

 

[CDW6212R]

How much are those EGR valves, and clogged was it using too much fuel that way?

 

[Number4]

EGR was clogged, to the point it set a code. Which means it's been running some time at lower efficiency.

EGR is pricy, but, how much $ have I lost over the years due to it, in gas?

 

[CDW6212R]

Yes, and my thought was about that too, without EGR(removed), is there any change of fuel mileage(tuned for it)? I've got a project planned for a Ranchero that I'd like to leave out the EGR. I only mentioned this since you solved your problem already.

 

[Number4]

I'm sure you can remove the EGR, but you'd have to get a tune as well if using the PCM for the engine.