When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
Have 2003 F350 4x4 6.0, 416K
code P401 is regularly on
Replaced ERG, new connector
Can clear the code and within 60 miles code is back
Any suggestions
Thanks
I have had the same problem with my ‘97 F250 with the 5.4L. There are quite a few YouTube videos on cleaning the Exhaust Gas Recirculation system. You may have to remove the intake manifold just under the throttle body. Buy yourself four or five spray cans of carburetor cleaner, long thin wire bristle brushes and even use pipe cleaners to manually scrub the small orifices. On the drivers side of the engine is a 3/4” to 1” tube connecting the exhaust manifold with the fresh air intake that can be a culprit.
I have had the same problem with my ‘97 F250 with the 5.4L. There are quite a few YouTube videos on cleaning the Exhaust Gas Recirculation system. You may have to remove the intake manifold just under the throttle body. Buy yourself four or five spray cans of carburetor cleaner, long thin wire bristle brushes and even use pipe cleaners to manually scrub the small orifices. On the drivers side of the engine is a 3/4” to 1” tube connecting the exhaust manifold with the fresh air intake that can be a culprit.
The EGR system on the diesels is quiet different than the gas engines. There is no tune that feeds from an exhaust manifold to the cooler. The EGR cooler connects directly to the passenger side up pipe and is bolted to the bottom of the intake manifold which for the unskilled is no small task to remove on an early production 6.0 Powerstroke. To the OP, I assume when you say you replaced the EGR you mean the EGR valve? If so did you use an OEM EGR valve from ford when you replaced it? Aftermarket units are junk.
P0401 is low EGR flow. The PCM calculates this by looking for a certain increase in the air temperature in the intake manifold (IAT2). That sensor gets pretty sooted up from the EGR flow. I recommend pulling it and cleaning and see if the problem goes away. It's on top of the intake manifold, just unplug and screw it out. See diagram below for location.
You could also have a restriction in the cooler or EGR pathway, but that isn't very common on the 6.0's. They usually just plug up the EGR valve which is easily removed and cleaned.
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.
