Ford Expedition

05-21-2005, 12:13 AM

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hi expo lovers!

i installed an open K&N air intake in my 02 expo. after 2 days...SERVICE ENGINE SOON light came on. if i remember right: P0401 EGR FLOW INSUFFICIENT.

Autozone told me "clean the egr valve" one mechanic told me its a pain in the ass to do and don't do it?!

any solutions, what i should do?

thanks

LVExpo

coryrhonda · 06-09-2005, 09:15 PM

D.P.F.E. sensor (EGR position sensor) It's the number 2 step on the newer revised trouble tree. first one is scan for a EGR code.

40eastvp · 11-23-2010, 01:20 PM

Heads up I have the same issue I replaced my EGR valve, EGR solnoid, DPFE sensor, and hoses I was just told by ford the EGR system is clogged and the want $600 to clean it.

**Nokturnal** · 11-25-2010, 01:49 PM

Originally Posted by 40eastvp

Heads up I have the same issue I replaced my EGR valve, EGR solnoid, DPFE sensor, and hoses I was just told by ford the EGR system is clogged and the want $600 to clean it.

well it probably is, they weren't just trying to bs you. There are ports that lead from the egr valve to the intake manifold that get completely clogged with black crap. It's a pain to clean them out. Easiest way is to just pull that 90 degree neck off and clean them with it off the vehicle, it takes some time to pull off but it's definitely worth it. When I did my expedition's they were literally clogged shut, and the ports are around the size of a pencil if not bigger. Took lots of prodding/scraping/carb cleaner to get those things clean..

**KWT2000** · 11-25-2010, 03:29 PM

the DPFE as said above is the most common colprit here and if some one puts regular vaccum lines on it instead of neopreme lines they don't last long as the rubber lines break down due to the heat

Jdbayy1 · 12-22-2010, 05:13 PM

It’s a common problem. My 97 Expedition with about 115K at the time was popping off codes and I got all the info to replace everything. I read about the Throttle body passages being clogged so I removed it and sure enough after I cleaned it, I saw where passages were supposed to be. I really had to dig at them to get them cleaned out. When I did, no more codes! Cost? My time and some cleaner! Easy job.

riccoh · 12-28-2010, 02:35 AM

don't waste your money on a shop if you are a bit mechanically inclined, here is the fix, all you will need is to removed the TB and get the botom ports cleaned, trusme a few gaskets and some TB cleaner did the trick for me when I followed this tutorial.. just a bit time consuming, takes about 1 HR, and a metal clothes hanger helps too. I needed it because there was no way that just the TB cleaner was getting pass the blocked ports.

http://www.fordf150.net/howto/throttlebodyclean.php

Good luck and tell us if this helped you

**markanthony** · 12-29-2010, 04:24 PM

On Most of the K&N oiled air cleaners. The oil fouls up the system. My nabor has a 97 and tried one. He replaced all the intake parts and had the same problems. He took of the oiled filter and put on a non oiled filter. Never had the problem again.

**Reconracer** · 01-18-2011, 11:40 PM

K&N =

Scotty B · 07-20-2011, 12:04 PM

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I've got a P0401 (insufficient EGR flow) code on my 97 Expedition with 5.4L engine and chasing down the problem too. I'm working from cheap and easy to the more expensive and time consuming options. I Seafoamed the engine to start. Figuring that'd clean some of the TB carbon out and possibly some vapor of the SeaFoam would recirc back up to the EGR. Didn't work, put idling better now anyway.
Yesterday I took off the DPFE and the two hoses coming from the EGR exhaust. There was carbon in hoses and DPFE. Hoses didn't have hole. I cleaned out the carbon deposits. The larger hose was somewhat collaped, so I was guessing that'd be the problem and went to Autozone to buy new hoses and DPFE.
I installed the new hoses first, just in case that fixed the problem (and I'd be able to return the new DPFE). Went for a test drive and the hose on the first port blew off. I'm now guessing the pressure is due to a lack of vacuum through the EGR, not a faulty DPFE.
I went to take off the EGR valve to clean it and the darn fitting from the exhaust side of the valve is siezed up tight. Anyone had this problem? Even if I took the TB off, the two 10mm bolts holding the TB to the EGR are siezed up. Its like both sides of the EGR have told me to buzz off. Anyone have this problem and what did you use to loosen it up?


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Ford Expedition

EGR Flow Insufficient