Hi Guys,
Im getting really tired of this code popping up.The EGR valve was replaced a few years back,and I still get this CEL code.Im fixing to go in,and clean some stuff out. I looked at it today,and from what I can see,there is about a 3/4 inch steel line running from the EGR assy to the rear of the passengers side Exhaust manifold....The other end of the EGR assy seems to disappear behind it(im assuming directly into the intake)....This is a 4.2 Automatic LWB.
I need to know what gaskets(if any) I need to have on hand before tearing this down,and what am I going to run into once the EGR itself is removed....The EXACT code definition is "insufficient EGR flow Detected).
I know this code has been beat to death,along with the other one im getting(evap emissions gross leak detected)..Figure Ill tackle the EGR first

 

I fought the EGR code for a while, also. Most issues EGR issues are because of a faulty Pressure sensor. This is an easy change. In fact, I had the issue a few times, replaced the DPFE sensor. The check engine light came back on a few months later. Had me scratching my head. I finally exchanged my sensor under warranty at Autozone. And I also replaced the two rubber vaccuum lines connecting to the sensor. A few months later, same thing happened. Ended up swapping it again. I think the best bet is to suck it up and get an OEM Ford Sensor as the aftermarket ones, I am on my third in a year. Autozone is cool about it, but it is a hassle.

 

Thanks for the reply,I generally dont "Do" Autozone for anything except Batteries,and oil...Ive read on some posts that the DPFE sensor replacement did not fix the problem,and that this was in fact a carbonization issue in the EGR system itself.Not saying the sensor isnt bad,but wanna get the carbon out of the way first...

 

My buddy had this problem, I fixed it by removing the EGR valve, then got some multi- strand wire (about a foot) unwinding "fraying" one end,chuck it up in a drill, use some carbon cleaner spray, spray the hole and spin the wire in the hole as far in as you can, blow out with air and your done ,good luck

 

Your thinking is a bit narrow on the subject.
A P0401 code is just the end result of reporting a failure in the "SYSTEM" not what part has failed.
The system involves the following and any one (or more) part's failure can result in the 401 code, so you need to look at the whole system and not just one part or point.
1. VACUUM REGULATOR control valve between vacuum and the EGR valve.
2. The EGR.
3. The DPFE, it's hoses, and plugup cable.
4. The metal exhaust piping.
5. Intake manifold port opening.
An added benifit is to know how the computer operates this system to find a low flow condition because it has to use all these parts to perform the function and detection testing..
Good luck.