I decided to try to fix my old original ford DPFE unit...NOT replace...FIX! It worked.

After buying a new NAPA DPFE for the 98, F150,4.6L,2x4, 135K it was still throwing a constant CEL 1410. Drat!
After much diagnosis the new DPFE purchased was "suspect". So, not wanting to buy another new PTFE I decided that it was worth the effort to try to fix the old original metal boxed unit that was throwing codes 0401 and 1401.

Here's how I fixed that DPFE (sorry no pics. I thought it was total folly at the time but it worked):

The body of the PTFE is held together by 6 recessed steel rivets.
Drill rivets out enough (not from the head side) and push the rivets out with a nail punch. DONT drill all the way through the PTFE body as you will destroy some rubber gaskets you will need for reassembly.
Carefully pull apart the 2 body halves.
I noticed lots of white crud (and some black slime) in there and blocked ports.
Used appropriately sized drill bits to clear the ports. To do this set body half in soft jaws of vice, You don't have to be jeweler delicate but don't be rough either.
Carefully pull the ceramic sensor up (round white disk) and soak body halves overnight in a 50/50 water/distilled vinegar solution in a small glass bowl. A dental pic to remove any corrosion in gasket seats helps too.
I propped up the sensor (kind of standing up) and taped so electronic components never touched the weak acid vinegar solution. Be careful no electronic parts touch your acid bath. I hope that makes sense?
Rinse with fresh water and let dry completely (again, not the electrical parts).
Push the round whitish ceramic sensor back into position.
Put 2 outer body halves back together and drill out the holes (no gaskets).
Separate the 2 halves and blew out any junk from drilling.
Install rubber gaskets back carefully and put the 2 halves back together.
Use (6) 1 1/2" bolts and nuts to hold the 2 body halves together (any that fit will do).
Use a little of the Red LocTite on the bolts/nuts so it stays together.
Reinstall hoses and electric clip.
Reset codes.
Go for a drive or 3.

This sounds like a lot of work but its not. Just give it a little care and it might work for you. I spent longer figuring out what to do than actually doing it.

I do not know how long this "fixed" DPFE will last but my plan is to only replace it with the updated version from FORD. I'm going to think twice before I buy anything electrically related from NAPA again.

For those that provided opinions, assistance and diagnostics, I can only say THANK YOU!!! You know who you are and have my utmost admiration, and sincerest appreciation.

I thought somebody might be able to use this information down the road. Just remember your mileage may vary.

 

Thats "DPFE" above not "PTFE".

 

Hey thats cool that you managed to fix it! Hope it lasts for you!

 

UPDATE:
I have put another 2K miles on this vehicle and no CEL has returned. Truck runs well and all seems fine for now.

***as he crosses fingers, and walks while not stepping on sidewalk cracks ***

 

Thanks for the tips, I will try it and let you know how it goes!

 

My apologies but what is a DPFE?
CEL is error codes? Right?

 

I beleive its "Differential Pressure feedback EGR". If you do a search on DPFE you will get all you care to read on it. Basically its a sensor that takes exhaust gas and measures that it is within tolerance...only problem is that it goes bad itself.

 

Well I followed your instructions and installed last night. I will let you know how it works out! It seems that the white crud (no idea what it is) interferes with the ceramic sensor. Once its cleaned out, the pressure sensor probably works fine again. THANKS for the tips!

 

Yes; let us know if it works for you. Don't forget to reset your codes.

 

96' Explorer. What have I got to loose? I'm a licensed electronic tech. I know how to drill. With your instructions, its gotta work, RIGHT??

Will get back to you. Z" 05/29/2007
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I think "hopefully work" is a better mindset.

A few folks have privately responded that it has worked for them...so your odds appear favorable. It's certainly worth a try.

If possible, can you take some digital pics along the way, and post if you are sucessfull? I can help you get pics uploaded to a server where you can post them here.

Good luck.

 

I've got lot of pics. You wanna see 'm before you tell me where and how to upload 'm? Your email?

Z"

 

HZ, glad you took pics!!! More importantly did it fix the DPFE? Has a Check Engine Light gone away?

We will discuss posting those pics soon. I will try to pm you.

 

Heck yeah, get pics up! I don't want to have to spend another $100 if I don't have to!!

 

Ive driven about 800 miles since the cleaning procedure and no rough idle or CEL light. Good job!