Gotta 2002 E-250 with a 4.2 liter.Put new intake gaskets on it and after driving for bout two weeks noticed a burning rubber smell.Found the DPFE switch hanging by two hoses.Larger hose was melted.Went to hook it back up and noticed that the tube to the larger hose was really hot.Looked in the Chiltons manual and it appears that this switch is measuring a pressure drop across an orifice in the EGR tube.What would cause this to get extremely hot and melt the hose?Any help would greatly be appreciated.

 

That's fairly common, the sensor has failed. The sensor erodes internally allowing hot exhaust gas to flow through it. Normlly, the sensor measures pressure but the hot gasses don't actually flow through it. Replace the sensoe and the hoses if they are damaged. The hoses are a heat resistant silicone, don't use regular fuel hose as it will burn off quickly.

 

Thanx for the info......