5.4L Lean code head-scratcher
Thanks for the kind acknowledgment. I sincerely hope I've provided some info that proves helpful. I am confident you will not regret having access to the additional diagnostic information the Torque Application and the Bluetooth interface tool will provide you.
However: encyclopedias can be written about what I don't know. It is easy to mistakenly jump to premature conclusions based on information obtained from OBDII codes and readings we can get from Torque (or from what some whacco FTE member says).
The Mode $06 data readings you're getting -TID $41 CID $12 - are HEX numbers along with the upper / lower acceptable reading range - that are (as I understand it) generated by the PCM from factory programmed standard operating parameters. The Torque App reply of "FAIL" (as I understand it) is just a logical report generated based upon the present reading if its outside the upper/lower range for that TID. [Actually, I would have thought 'that' should set the ECL, but ??? it doesn't always, SO, that is one other thing I don't know]
Be sure to have your vehicle 'characteristics' set up properly in Torque setup. And look for and install any "custom PID's" for Ford Trucks. I think the stock program has 90% of the, but I know Mode $06 is VERY vehicle specific.
I notice my truck ('04 5.4L), Mode $06 report doesn't have TID $41. That would be because it does not have an EGR valve, or a DPFE. So that's all above my pay grade - lol.
I am, however, willing to bet that an EGR not closing off good could cause a lean condition and a funky idle. I would recommend setting up some custom gauges on Torque and monitoring anything you can think of that affects or is affected by the DFPE valve or EGR valve and try to think up creative ways to challenge the sensors being monitored on Torque. I believe you can narrow it down pretty quickly.
Be a little slow and cautious about making snap (or expensive) decisions from the large volume of information we get from the Torque App. These late model vehicles have so many design variations that almost no one (even Torque) can keep up with it. I chased a rabbit trail for a long time - and spent several dollars - and finally found out that my truck does NOT EVEN have a coolant temp sensor. It ONLY has a Cyl Head Temp sensor, and the PCM "extrapolates" coolant temperature for the dashboard from Cyl Head temp sensor!!!!! Then also, the Torque App showed a sensor designated "Cyl Head Temp (alt)" ----- that would read from 2500 degrees F up to 13,000 degrees!!!!! I finally found out my truck has a CMCV. ????? (Charge Motion Control Valve). And the PCM outputs 0 to 5 volts to control that actuator valve that Torque thought was a TEMPERATURE SENSOR!!!!!! DAMN. Drove me crazy. Now I'm working on developing a correct formula to input in "Manage Custom PID's" screen on Torque to convert this signal correctly so I can display it on a gage showing percentage open of the CMCV butterflies in the intake ports. (At least Torque is flexible enough to handle this vehicle specific variation.)
Good luck.

Thanks again for the input & advice.



