I am the proud new owner of a '98 Expy 4X4 with the 5.4, courtesy of the U.S. Border Patrol. It's a tad rough, but not too bad with 75k miles. Check engine light came on, so I plugged in my trusty Creader from Harbor Freight Tools. It came back with an 0401, which is said to be "Exhaust Gas Recirculation Insufficient Detected". Am I correct in assuming the EGR passages or the valve itself are clogged? If not, what are the common problems I would check that would throw that code? I'm familiar with engines in general, just not the 5.4. If anyone wants to go into any detail or talk off-forum, please email me at big4door@ev1.net. Thanks for this great forum and any help.

 

There are some good threads in FTE forum on EGR problem if you search for them. Sorry that I am not more specific for you.

 

It's either a bad DPFE sensor or clogged EGR passage. Apply vacuum to the EGR valve while its running. If the passages are clogged nothing will happen, if the are not, the engine will try to die or stumble real badly. If it stumbles, change the DPFE and hoses.

 

Thanks for the tip! I gotta get a little vacuum pump to give it a shot, but I could use one anyway. Is it more commonly the DPFE or the EGR itself?

 

Most common problem is the DPFE

 

My generic code reader was stumped, so I brought my '00 E150 4.6 to the dealer. They read the above codes, and decided I needed a dpfe sensor & a "decarbon EGR port" - $750.00. Plus, they recommended a drive belt ($150) and a battery ($125) - $1025 plus tax.

I said thanks for the codes, bought a belt from NAPA for $45 and brought my van home. I don't have a driveability problem, so I'm letting my wifey take it on a trip tomorrow, but when she comes back, I should replace the DPFE sensor ($45?) and clean the egr valve port?

Take the EGR valve out and clean the port that it's attached to maybe? Or jst shoot carb cleaner down the intake hose?

Anybody with a recommendation?

BTW, my belt with 83K on it still looked great. A bit browner and longer than original, but otherwise great. The belt replacement process was easiest ever!

Dave in Miami

 

I suffered through the same problem with code P0401. I changed the ERG Valve and the PDFE switch and it did not fix it. The light came back on in a few miles, but I finally fixed my 98 4.6L F150 with 112,000 miles by cleaning the ERG ports. The ports I'm speaking of can only be accessed my removing the throttle body elbow off the top of the intake manifold. It's an elbow that connects most of the vacuum lines including the ERG Valve. I got a lot of carbon out of their using a drill bit by HAND and that fixed it. There is a simple test to tell you if the ports are clear.

Remove the vacuum line from the ERG Valve and cap the hose. Start the engine and let it idle. Then apply vacuum (outside source) to the ERG Valve. The engine will stumble or stall if the ports are clear. If the engine continues to idle without change the ports are blocked and need to be cleaned. I cleaned mine in about an hour it's not that big of a deal on the 4.6L