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Old Jul 21, 2012 | 12:18 PM
  #1  
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P0401

2001 f150 XLT 4.6L, code P0401 (100,000 miles) 4X2 Supercab with longbed
Everything (EGR valve, pressure sensor and the solenoid)has been changed a couple of times. TB and vaccum lines have been cleaned out, voltages have been checked out. reset code drive anywhere from 7 to 25 miles and the service engine light comes back on. take it back to Pepboys and it has the same P0401. They have tried everything that they can think of, and cannot figure it out. Any suggestions??
Thanks, Bob
 

Last edited by Bobbug; Jul 21, 2012 at 12:28 PM. Reason: add 4X2 XLT
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Old Jul 21, 2012 | 04:52 PM
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Have the TPS checked. A bad TPS can send the wrong signal and cause the EGR to malfunction
 
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Old Jul 21, 2012 | 05:14 PM
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Thanks, I will suggest that when I see them Monday
I forgot to mention that everything seems to be running correctly, smooth, no stalling, no rough idle, just the service engine soon light keeps coming on.(P0401)
 

Last edited by Bobbug; Jul 21, 2012 at 05:53 PM. Reason: forgot to mention
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Old Jul 21, 2012 | 06:34 PM
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Most of the time that code is the dpfe sensor. I had the same code and I replaced dpfe with a motorcraft part and i haven't seen the light since. I've heard aftermarket ones are crap.
 
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Old Jul 21, 2012 | 07:16 PM
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Does the engine stall when you apply vacuum to the egr? I call it the suck test, because I put a vacuum line on the egr and suck on it to open it
Next is egr tube broken off header?
Tee in vacuum gauge at egr ,vacuum should be 1ingh idle, a pulse to 3 to 3.5 ingh in a slow rev
Tape it to the windshield and go for a drive see if it opens to 5 to 7 ingh

Dpfe hoses in right spot
Blocked orafice inside egr tube between the hose ports
 
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Old Jul 21, 2012 | 09:44 PM
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Hint, don't use Pep Boys DPFE, only Ford OEM part.
The test conditons are to tight for many aftermarket units that are out of tolerence as mfgered and sold to these stores.
The 401 code is a 'test failure' for EGR system flow within tight tolerence levels.
The test is run two times during each drive cycle. Once at startup and once during the drive.
So you can clear the code and it will come right back if not corrected the next time you start the engine and drive off. The second test failure lights the CEL..
Good luck.
 
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Old Jul 21, 2012 | 09:55 PM
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Thanks to all. I will be requesting Ford OEM part. I had suggested it before, but now I will be more forceful, and take nothing but. This has been going on since Feburary, and I have had it.
Thanks again to all.
Bob
 
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