2000 Windstar 3.8 Ltr. code P0401

[gasmith46]

I have a 2000 windstar 3.8 Ltr. eng. Trouble code P0401, EGR flow insufficient
Before I replace the EGR valve is there anything I should look for first?

[wiswind]

Common causes for P0401 is clogged EGR ports in the lower intake manifold, which requires removal of the upper intake manifold to clean.
There is a passage inside the lower intake manifold that goes from the EGR valve to a port at each cylinder. The ports become clogged, usually starting at the ports closest to the EGR valve (#3 and 6).

The other common cause for P0401 is the DPFE, which senses the EGR flow through the pipe that goes from the front exhauste manifold to the EGR valve.
Easy to change.

The EGR valve it's self is NOT a common cause of the P0401 code.
Is worth checking the vaccum line connection to the top of the EGR valve.

The 2000 year is included in the TSB that is well covered in the information in this link.
http://leckemby.net/windstar/windstar01.html

[OldFaithful]

If your DPFEGR sensor is metal (aluminum), I would definately suspect it as the cause of your PO 0401 code. I have two 2000 Windstar and both have required replacement of this sensor to cure this code.

It sets on the front side of the engine as oriented by the front of the car, has one electrical connection and two smallish hoses coming up from the EGR supply pipe and one of those is a slightly larger diameter than the other. The pipes on the bottom of the sensor are also different diameters to match the correct hose. Don't get the hose connections switched or your computer will never figure out the what is going on.

The acid in the exhaust gas gets right to that aluminum. The new revised sensors are of a plastic body. I purchased one of the new models from NAPA parts store but when I went back for another, they only had a new aluminum model and so I went to the Ford parts and shelled out more than twice as much money for the plastic version, about $128.00 USD as I remember. That really frosted me but spending half on something that I new would fail just didn't seem reasonable to me.

Cleaning out the EGR ports that are in the metal lower intake manifold and are exposed to view and clean after the removal of both parts of the upper intake manifold is a good idea particularly if it has not been done yet.

Do the search for these items on this forum and you will find some good information to use complete with pictures.

Good luck.

Jim