This is new to me as I have allways owned 78-79 Ford Truck models,but just recently bought a 2000 F-150 with 4.2L.My CEL came on only after 2 weeks of owning the truck,my local A Zone checked it and it came up as EGR insuffient flow.I have read alot of responces on FTE about this problem,but could someone please tell me what I should check first all the way down to the last and how to do it properly,what should or should not be replaced,and the estimated cost of the components.The 79 was so much easier to work on,it either ran or it didn't.I really appreiciate your help.

 

I would first go to the dealer and have them check it out. If it is a DPFE bad, there is a program extending the warranty on them for free replacement on certain model years.

 

SUBJECT: Customer Satisfaction Program 02M01: Certain vehicles equipped with a tube-mounted EGR Pressure Sensor - Additional EGR Pressure Sensor Warranty Coverage



OASIS:
Yes

OWNER LIST:
No

PROGRAM TERMS:
This additional coverage program will add 2 years or 24,000 miles whichever occurs first, to the base warranty coverage for the tube mounted EGR Pressure Sensor. This coverage will automatically transfer to subsequent owners.


VEHICLES COVERED BY THIS PROGRAM

Certain 2000 and 2001 model year vehicles equipped with a tube-mounted EGR Pressure Sensor (9J460). Refer to OASIS for specific vehicle eligibility.

TIME AND MILEAGE LIMITS




Warranty Type
Current Warranty Coverage
Total Warranty Coverage

Federal
3 Years/36,000 Miles
5 years/60,000 Miles

California Emissions*
3 Years/50,000 Miles
5 Years/74,000 Miles

Lincoln
4 Years/50,000 Miles
6 Years/74,000 Miles


* California emissions include vehicles certified for sale in California and registered in California, Maine, Massachusetts, New York or Vermont.

REASON FOR PROVIDING ADDITIONAL COVERAGE

Vehicles experiencing a problem with the tube mounted EGR Pressure Sensor may exhibit a Malfunction Indicator Light (MIL) along with one or more of Diagnostic Trouble Codes (DTC) P0401, P0402, P1400, or P1401.

A very small percentage of vehicles may also exhibit a MIL with the following symptoms:

Hesitation/Surge
Stall with restart
Any of these conditions will not cause engine damage or failure, but may decrease the customer's satisfaction with their vehicle.

SERVICE ACTION

It is recommended for vehicles exhibiting any of the conditions listed above and equipped with a tube mounted EGR Pressure Sensor, that the dealer retrieve continuous DTC prior to any other diagnostics.

Dealers are to install a new tube mounted EGR Pressure Sensor at no charge to the owner of the vehicle, ONLY if one or more of these continuous DTC are present:

P1400 - DPF EGR Sensor Circuit Low Voltage Detected
P1401 - DPF EGR Sensor Circuit High Voltage Detected
P0401 - EGR Flow Insufficient Detected
P0402 - EGR Flow Excessive Detected
A failed DPFE will only exhibit one or more of the DTC listed above. This program will not cover any other continuous DTC present

 

I had the same code on my 98 F150 4.6. I checked the DPFE sensor, EGR valve, Vac Reg Solenoid, and all that. Everything was working as it should. The insufficient flow code is more likely to be because of the build up of carbon where the EGR gases enter the intake manifold. They are typically small diameter ports and are prone to carbon build-up over time. I cleaned mine thouroughly (see my post in General Performance) and the code has disappeared. Passed NJ State Inspection this morning with flying colors.

The main thing that I can relay to you is that when I put vacuum to the EGR with it running, it should have stalled and it didn't... it just ran a little rough. The reason was that the EGR was doing it's job, but the gases couldn't get through the blockage in the intake. Not sure how your engine is set up, but I'd be willing to bet that the same thing is happening to you. I would check out the carbon-blockage situation first.

P0401 is a generic code, the Ford-specific code for Insufficient EGR Flow is P1408. You may want to have someone with a better scanner do the scan. Autozone uses the generic scan tool and it doesn't tell you the specific code- just the general P0401 code. I had a friend use a Mac scanner with Ford-specific module plugged in and got the P1408 "Insufficient EGR Flow" code. which means exactly that-the flow of the EGR gases is insufficient, usually due to a blockage in the passage. Couldn't see the blockage in my 4.6 until I removed the Throttle body and upper intake elbow. Then it was apparent!

So my advice is to get it scanned with a better scanner, then check for the carbon blockage if the code really is P1408.

 

I really appreciate all the help,I think I will do a little research and purchase my own scanner that will read specific codes.Know of one at a decent price?