1996 7.5 DPFE problem
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Mountain Pass
Joined: Dec 2006
Posts: 196
Likes: 1
From: INYOKERN, CALIFORNIA
1996 7.5 DPFE problem
Hey everyone! Well, I have been doing pretty well with my 1996 F350 w/ a 7.5 E4OD. I found a set of new Motorcraft injectors on EBAY, and bought and installed those last week. That solved the problem I had when the truck was really cold, it just would not go over 2000 RPMs, until up to operating temperature. Well, when I had it apart I broke a couple nylon vacuum lines and repaired them, truck ran very well, but set a CEL code P0401, which I believe is EGR low flow related. So I rechecked everything, found all was hooked up right, and decided to replace the DPFE sensor. I went to my local Ford dealer and they sold me a Motorcraft DPFE 15 sensor for $117.00. I asked the parts man if I could get new hoses and he said they were just bulk vacuum line. So after getting home I look at new and old DPFE sensors and discover that the ports that the hoses from EGR supply tube to DPFE are in different locations than my OEM sensor. The metal EGR supply line and the ports on new sensor are no where near close, and I think if a guy tried to bend on this line, it would more than likely either kink or break. So long story short, Ford say's that's the right sensor, and it's up to me to do whatever I need to do to make it work. Anyone else ran into this? Thanks! Dale
Fleet Owner
Joined: Oct 2005
Posts: 20,789
Likes: 1,753
From: Kentucky
There is no reason to bend the metal sample tubes on the EGR line. The hoses connecting the DPFE to those sample ports are not standard vacuum line they are made of high temperature silicone and more than like the ones on your truck may be faulty. Find a different dealer to source replacement hoses.
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Mountain Pass
Joined: Dec 2006
Posts: 196
Likes: 1
From: INYOKERN, CALIFORNIA
Hoses
Thanks for your reply, I was probably not clear enough, as to the nature of the problem. I will take some pictures and try to post them, or I can send you a PM, and exchange email addresses, and I can send you the pics. In a nut shell, the old sensor had the sample tubes port and starboard on the bottom of the sensor body, the replacement sensor has the tubes fore and aft. I think I am going to have to cut the sample lines shorter and run some silicone vacuum hose with a gentle curve to attach to the new DPFE sensor. Thanks for taking the time to respond! Dale
Fleet Owner
Joined: Oct 2005
Posts: 20,789
Likes: 1,753
From: Kentucky
That is odd Ford changed the DPFE that much. I understood your problem statement in general terms, but I have never seen a DPFE equipped 7.5L engine to know how close the EGR tube sample ports are to the DPFE sensor. I think Dorman carries the high temperature silicone tubing in bulk lengths.
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Mountain Pass
Joined: Dec 2006
Posts: 196
Likes: 1
From: INYOKERN, CALIFORNIA
DPFE
Well, the California emissions 1996 7.5 are different animals. The DPFE mounts right beside the TPS on the side of the upper plenum. The EGR supply tube comes from rear of L/H exhaust manifold, and the 2 sample tubes branch off of it at the rear of L/H valve cover. They have a brace welded between the sample tubes and I don't see any success in trying to bend them enough to connect to the new style DPFE. So I am going to get some of the orange silicone vacuum line and trim back the sample tubes and run the 2 hoses up to DPFE. Thanks! Dale
Fleet Owner
Joined: Oct 2005
Posts: 20,789
Likes: 1,753
From: Kentucky
Those Cali. emission trucks are a bit rare. I knew they had MAF and DPFE EGR feedback but I never saw one in real life and pics on the 'net are tough to track down. I still wonder if the Motorcaft DPFE they gave you is the correct one.
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Mountain Pass
Joined: Dec 2006
Posts: 196
Likes: 1
From: INYOKERN, CALIFORNIA
DPFE
Well, I called a couple more dealers in SoCal, and they all agreed that the DPFE sensor , Motorcraft DPFE 15, is the proper replacement sensor. So I went to town and bought 2 different sizes of the hi-temp orange silicone vacuum line. Only problem was that CarQuest makes you buy the package (6 ft.) so it cost $31.00. So once I started looking at the engine after I removed the old vacuum lines, I saw that there was room to run a big loop of the larger size line to connect the sample tube to the port on the sensor. It just looks sorta funky, but, it works and trucks runs well and no CEL! I appreciate your responses! If you want to see some pics of the set up, send me a PM with your email address, and I will send you some pics. Thanks a bunch! Dale
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Freshman User
Joined: Oct 2012
Posts: 28
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From: mesa, az
hey i have the same rare truck and cannot find anywhere thats supplies a pic of the emissions routing. maybe could you take a few detailed pics of the engine? where it all goes and connects. and what prey tell is a dpfe? i went from a powerstrokr to this truck and relearning spark control is killing me.
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Thread Starter
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Mountain Pass
Joined: Dec 2006
Posts: 196
Likes: 1
From: INYOKERN, CALIFORNIA
DPFE
Jon, I have not had any luck posting pictures here yet. If you send me a private message, I will send you my email address and get some engine compartment pics to you that way. A DPFE is Fordtalk for Differential Pressure Feedback EGR. I am still getting random codes set for EGR related issues, however truck is running pretty well, but that's another issue all together! Thanks! Dale
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