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P0401 EGR Questions

jam1ej20

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February 25, 2015
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Year, Model & Trim Level
2007 Ford Explorer
My 2007 explorer 4.0 V6 is throwing P0401 codes. I'm trying to troubleshoot the system but am unsure as to how the system should operate and what to look for.

I know that I have vacuum on both hoses going into the DPFE and I'm not sure if that's correct or not. Should I be looking for other issues?

Is there a way to test the EGR or DPFE without a computer scan tool?

Thanks
 



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There are videos on the internet showing how to test the DPFE, I tested mine and it was within range testing good. But I still got the code after about 10 miles driving after I cleared the code. I ended up changing the DPFE and then cleaning the MAF sensor with MAF cleaner. I also removed the throttle body and cleaned it, it was filthy. It was a PITA, but if you have patience, it was not hard to do.
 






There are videos on the internet showing how to test the DPFE, I tested mine and it was within range testing good. But I still got the code after about 10 miles driving after I cleared the code. I ended up changing the DPFE and then cleaning the MAF sensor with MAF cleaner. I also removed the throttle body and cleaned it, it was filthy. It was a PITA, but if you have patience, it was not hard to do.

The DPFE is not serviceable on my 07. It is integrated into the EGR valve. The only testing videos that I was able to find for this setup involved a pretty fancy computer setup that simulated conditions and provided voltage outputs on the screen.
 












EGR Valve leak

Check between Egr Valve and where it connect to the intake manifold and throttle Body for leaks. If you have a leak, your o-ring gasket is worn out and need a new one. Good thing is they cost about $2.00 and easy to replace. Good luck!!!!
 






Got the same code today. Lol! Yay me! Will have to check it out on my next day off though. Hope it's just a leak or something that can be cleaned out. I hate spending money on this thing already.
 






Egr valve leaks

My Explorer had the same code and it was a leak in two places. 1. Was the gasket between egr valve and throttle body. It looks like a green o ring. 2. Was the egr valve gasket and it looks like a metal piece or could be a regular gasket. Use a piece of garden hose about 3-4 feet to listening for the leak. One end to your ear and the other to check around for leaks. If you have a leak you will hear it this way, that's how I found mine. It will cost you about $5-$25 to fix it yourself. Good luck!!!!
 






My Explorer had the same code and it was a leak in two places. 1. Was the gasket between egr valve and throttle body. It looks like a green o ring. 2. Was the egr valve gasket and it looks like a metal piece or could be a regular gasket. Use a piece of garden hose about 3-4 feet to listening for the leak. One end to your ear and the other to check around for leaks. If you have a leak you will hear it this way, that's how I found mine. It will cost you about $5-$25 to fix it yourself. Good luck!!!!

got the code while driving. truck made it home (about a 5 minute drive) no problem. after i scanned and retrieved the code i cleared the code, started the truck and idled for a minute. the code didnt come back. didnt have time to drive it around the block yet. i will try the garden hose trick.
 






I replaced the EGR valve and haven't had the light come back on. Mine only had the metal gasket, no orings or other seals that I saw. It's not terribly hard to change. The EGR valve has the DPFE built on to it so there's more than one component that can fail. It's a likely bet that changing the part will fix your problem. However, it's always smart to check for a vacuum leak first, those vacuum tubes are pretty thin and can easily crack or become damaged.
 






I replaced the EGR valve and haven't had the light come back on. Mine only had the metal gasket, no orings or other seals that I saw. It's not terribly hard to change. The EGR valve has the DPFE built on to it so there's more than one component that can fail. It's a likely bet that changing the part will fix your problem. However, it's always smart to check for a vacuum leak first, those vacuum tubes are pretty thin and can easily crack or become damaged.

Will do. How do you see back there. Looks like you have to lay down on top of the engine to view that space where the EGR is mounted. Lol
 






Will do. How do you see back there. Looks like you have to lay down on top of the engine to view that space where the EGR is mounted. Lol

I removed the top of the air filter and the big, flexible intake pipe. Then I removed the throttle body. Once you remove this two pieces, it's a lot easier to get to the EGR valve.
 






Just ordered a Motorcraft EGR from rockauto. Should get it by early next week. We'll so how it goes from there. Thanks for the info.
 






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