We took a f250 diesel early build 2003 into a small shop and they told us we had to go to a dealer. The codes that came up were P0401, P0402, P0404, AND P1335. They said we need an EGR baffle kit and that only Ford can do it since their is special programming needed on Ford can do. I got home and started reading the complete write up and noticed in large letters it said "ONLY INSTALL THE EGR BAFFLE KIT IF THERE IS EVIDENCE OF WET OIL". I cleaned the EGR before taking it in and it was dry and only had very little soot on it. I also cleaned the IAT 2 sensor and it was a little gummy. The truck has no power, we live two miles from the shop and we are in the hills. On flat ground we hit 45 MPH, when we hit a hill we would be lucky to be at 30 MPH at the top. Any idea's out there, I was ready to take it to Ford until I read the complete write up.

 

I have never heaRD of an EGR Baffel kit

but heres the code deffinitions

<TABLE style="WIDTH: 729pt; BORDER-COLLAPSE: collapse" border=0 cellSpacing=0 cellPadding=0 width=972><COLGROUP><COL style="WIDTH: 77pt; mso-width-source: userset; mso-width-alt: 3730" width=102><COL style="WIDTH: 86pt; mso-width-source: userset; mso-width-alt: 4205" width=115><COL style="WIDTH: 237pt; mso-width-source: userset; mso-width-alt: 11556" width=316><COL style="WIDTH: 281pt; mso-width-source: userset; mso-width-alt: 13714" width=375><COL style="WIDTH: 48pt" width=64><TBODY><TR style="HEIGHT: 25.5pt" height=34><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black 0.5pt solid; BACKGROUND-COLOR: transparent; WIDTH: 77pt; HEIGHT: 25.5pt; BORDER-TOP: black 0.5pt solid; BORDER-RIGHT: black 0.5pt solid" class=xl66 height=34 width=102>P0401</TD><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black; BACKGROUND-COLOR: transparent; WIDTH: 86pt; BORDER-TOP: black 0.5pt solid; BORDER-RIGHT: black 0.5pt solid" class=xl66 width=115>EGR</TD><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black; BACKGROUND-COLOR: transparent; WIDTH: 237pt; BORDER-TOP: black 0.5pt solid; BORDER-RIGHT: black 0.5pt solid" class=xl65 width=316>Exhaust Gas Recirculation Flow Insufficient Detected</TD><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black; BACKGROUND-COLOR: transparent; WIDTH: 281pt; BORDER-TOP: black 0.5pt solid; BORDER-RIGHT: black 0.5pt solid" class=xl65 width=375>EGR valve, EGR position sensor bias, EP sensor bias</TD><TD style="BORDER-BOTTOM: #f0f0f0; BORDER-LEFT: #f0f0f0; BACKGROUND-COLOR: transparent; WIDTH: 48pt; BORDER-TOP: #f0f0f0; BORDER-RIGHT: #f0f0f0" width=64></TD></TR><TR style="HEIGHT: 25.5pt" height=34><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black 0.5pt solid; BACKGROUND-COLOR: transparent; WIDTH: 77pt; HEIGHT: 25.5pt; BORDER-TOP: black; BORDER-RIGHT: black 0.5pt solid" class=xl66 height=34 width=102>P0402</TD><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black; BACKGROUND-COLOR: transparent; WIDTH: 86pt; BORDER-TOP: black; BORDER-RIGHT: black 0.5pt solid" class=xl66 width=115>EGR</TD><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black; BACKGROUND-COLOR: transparent; WIDTH: 237pt; BORDER-TOP: black; BORDER-RIGHT: black 0.5pt solid" class=xl65 width=316>Exhaust Gas Recirculation Flow Excessive Detected</TD><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black; BACKGROUND-COLOR: transparent; WIDTH: 281pt; BORDER-TOP: black; BORDER-RIGHT: black 0.5pt solid" class=xl65 width=375>EGR valve, EGR position sensor bias, EP sensor bias</TD><TD style="BORDER-BOTTOM: #f0f0f0; BORDER-LEFT: #f0f0f0; BACKGROUND-COLOR: transparent; BORDER-TOP: #f0f0f0; BORDER-RIGHT: #f0f0f0"></TD></TR></TBODY></TABLE>
<TABLE style="WIDTH: 729pt; BORDER-COLLAPSE: collapse" border=0 cellSpacing=0 cellPadding=0 width=972><COLGROUP><COL style="WIDTH: 77pt; mso-width-source: userset; mso-width-alt: 3730" width=102><COL style="WIDTH: 86pt; mso-width-source: userset; mso-width-alt: 4205" width=115><COL style="WIDTH: 237pt; mso-width-source: userset; mso-width-alt: 11556" width=316><COL style="WIDTH: 281pt; mso-width-source: userset; mso-width-alt: 13714" width=375><COL style="WIDTH: 48pt" width=64><TBODY><TR style="HEIGHT: 25.5pt" height=34><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black 0.5pt solid; BACKGROUND-COLOR: transparent; WIDTH: 77pt; HEIGHT: 25.5pt; BORDER-TOP: black 0.5pt solid; BORDER-RIGHT: black 0.5pt solid" class=xl66 height=34 width=102>P0404</TD><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black; BACKGROUND-COLOR: transparent; WIDTH: 86pt; BORDER-TOP: black 0.5pt solid; BORDER-RIGHT: black 0.5pt solid" class=xl66 width=115>EGR</TD><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black; BACKGROUND-COLOR: transparent; WIDTH: 237pt; BORDER-TOP: black 0.5pt solid; BORDER-RIGHT: black 0.5pt solid" class=xl65 width=316>Exhaust Gas Recirculation Control Circuit Range/Performance</TD><TD style="BORDER-BOTTOM: black 0.5pt solid; BORDER-LEFT: black; BACKGROUND-COLOR: transparent; WIDTH: 281pt; BORDER-TOP: black 0.5pt solid; BORDER-RIGHT: black 0.5pt solid" class=xl65 width=375>EGR sensor or valve, EGR position circuit</TD><TD style="BORDER-BOTTOM: #f0f0f0; BORDER-LEFT: #f0f0f0; BACKGROUND-COLOR: transparent; WIDTH: 48pt; BORDER-TOP: #f0f0f0; BORDER-RIGHT: #f0f0f0" width=64></TD></TR></TBODY></TABLE>

I would throw a new EGR Valve in it and see what it does
you can do it no need to reprogram stuff unless you want to deleate it
But you should be able to throw a new EGR valve at it and be fine no extra programming for EGR Valve replacement

and Welcome to FTE

 

I forgot to mention on the write it states the codes are in relation to a TSB regarding this issue. Does anyone know what a TSB is and could this be some sort of programming. The EGR I removed had very little soot and it was dry. It was not stuck open. Should I still install a new one?

 

I forgot to mention on the write up it states the codes are in relation to a TSB regarding this issue. Does anyone know what a TSB is and could this be some sort of programming. The EGR I removed had very little soot and it was dry. It was not stuck open. Should I still install a new one?

 

Even if the EGR valve is clean, it does no good if it's not opening/closing as commanded by the PCM under the varying conditions. The valve is also a position sensor incorporated into the valve itself. The only way to test its operation is to have what's called an Air Management test done, using Ford's IDS scan tool. I too, would be inclined to believe the EGR valve is in need of replacement, based on the information posted. If you are in the U.S.A. the part number is 4C3Z-9F452-A for you vehicle application. If you are in Canada, it is CX-2056.

 

I changed the EGR, no codes, no power. I drove it one mile, nothing. Turbo comes on but no power. Still no check engine light. I think I have to take it to the Ford dealership unless someone else can add something. $90 to get it diagnosed at a small shop to tell me it has to go to Ford, $200 for the EGR. What is next will really hit the pocket book.....Any ideas I am new to Fords....

 

Did you pull those codes on your first reply or is that just what the shop told you??

Sorrey about the EGR but all the codes on this side of the computer pointed to a bad egr valve

Do you have a code reader or a ScanGauge its 160.00 from autozone

If not it maybe the best thing to take it to ford and let them diagnose it

We could guess all day but your Bank acc. wouldnt like that

best thing is to test and check the varios sensors values see what ones out a scaan gauge is pretty good for this great gauge only

an Auto Enginuty is about the best for us DIY Guys lots of actual tests you could run with it also can check injectors with cylinder balance and also do a Buzz test and a bunch more testes but its like 360.00 from Clay at Riff Raff diesel
Every scanner or code Reader Iv ever bought has paid for itself sooner or later my SG has paid for itself a few times over

I beleive the ford dealer is around 100.00 to do a diagnostic

Pick your Poision

 

Thanks, it is going in. Now to make this all a little funny. I am a Chevy man, Duramax. I had one paid off and the X took it in the divorce. I found a lady and she has this Ford, this lady happens to be my wife's new boyfriend's X wife. WOW and we never knew!! Thanks for the help but this old Ford is getting fixed and we are ordering a truck from Dave Smith Motors in ID. Most likely a Chevy. You Ford people are great but the 6.0 is a bad unit, really bad.

 

WOW thats a small world for shure there with the X and what not

Funney how all that divorce Sh*** works been there done that

Alot of Truth to the fact She Got the Gold Mine I Got the Shaft

Let me Guess you got to keep all the stuff thats not paid For



Im not particular to any one brand auto But its got to be Ford or Chevy Had BAD Luck with Dodge
Iv had good luck with the Chevy cars Iv bought and Knock on Wood Iv had good run with my 6.0 too

 

Well we took it to the Ford Dealer and they came back with a bad EGR cooler, 3 bad injectors, and 2 blown head gaskets. I have replaced the EGR valve already. I am not a master mechanic but how did they figure out the head gaskets are blown? The oil looks good, I did loose a little coolant. The truck is now being towed home, they wanted 6K to fix it all. I am thinking about replacing the EGR cooler or just purchasing the block off kit. Any advice out there? I am in Oregon and we do not have to smog but will the block off kit make it hard to trade in? The truck will run but has "0" power, the turbo kicks in and nothing.

 

SEE IF YOU CAN SWITCH BACK VEHICLES AND KEEP THE PRESENT LADY

 

That would be great, the present lady is perfect and I never thought I would say that about a woman but she is. She just happened to own a Ford, not enough to dump her. Joking....

 

Head gaskets Easy compression check did they do it I doubt it I beleive to do a compresssion test they would have to pull the Glow Plugs Now in doing this they would have more than likely broke the GP harness and you would see that on your bill cuz they aint gona give em away for free
Does it puke out the coolant bottle???
Does it have sudden temp Spikes??? nd I mean temp gauge shooting into the red
these are signs of a bad head gaskwet

More Likely they ran a cyclinder balance test this is more likely cuz they can do it threw the OBDII pport VERY EASY
this is how they spot bad injectors

Another thing if the EGR Cooler was bad you would also need an oil cooler the oil cooler normaly fails first and then takes out the egr cooler

Plus you pulled the egr valve out and said it was DRY it should have been WET if the egr cooler was blown
Plus is it going thru coolant alot fill it up ll the time or what??:

I did just see you said it lost some coolant Did it puke out the bottle or do you have white smoke

 

No puking out the coolant, white smoke some. One time pulling up a grade from CA to OR it did spike hot. We were pulling a heavy trailer. Turned on the heater for 2 minutes and slowed down and all was well. This was 3 months ago.