egr valve 96 explorer xlt

[ConRon]

OK, check engine light goes off, code is 0401, i think, was told it said egr insufficient. Truck was running fine so waited til it wasn't. It started to bogg at Idle, so I replaced EGR valve. Ran fine for about 24 hours then started to bogg again. Had code read at autozone same code was still coming up,(but was never removed), 2 other codes were coming up, both were due to air/ gas combo. Decided to replace egr valve sensor. Check engine light went off, stayed off for a week, truck still bogging. Check engine light goes on again, code is 0720 I think. Says lean gas flow?? Truck still bogging at idle (only). Please help!!spending alot o $$ on unneccisary parts. Thanks, ConRon

[fordman123]

Just my take on this but,
it sounds like you have a bad IAC valve (engine idle) or some bad catalytic converters or O2 sensors (lean codes in PCM). I would recommend taking your Explorer to someone who knows what they are doing and pay them a few dollars, for, if nothing else, telling you what is wrong with your truck.

Fordman123

[V8X]

When you say you replaced the EGR sensor, did you replace the EVR Solenoid or the DPFE?

[franzh]

My sons 97 Explorer with 5.0 has a similar problem, but with the P-0402 code, excessive EGR. The Ford dealer wants $240 to replace the DPFE sensor which breaks down:
$80.00 diagnostics
$94.00 DPFE
$60.00 labor
Assorted shop fees.

I also have a 95 Explorer 4.0, and have replaced the DPFE twice in 150K miles, and its accessible, right in front. By them charging $60.00 labor, it cannot be too difficult, BUT! Its no where to be found! Its not where Mitchells on demand and Chiltons says it is. Ford will not tell me, just to "Bring it on in and we will fix it!"

I have used a mirror and strong lights. I can see the EGR valve behind the intake, plus the vacuum actuator valve, but the DPFE sensor is invisible. I do know what the replacement looks like, already purchased it. The Explorer is not with me except on monthly trips, so I cannot run out do do a quick look-see.

Ideas?

[V8X]

The DPFE for the 5.0L/302ci Explorer is between the firewall & intake manifold, at the top of the intake manifold. If you follow one of the tubes from the EGR Vaccum Solenoid, it will lead you directly to the DPFE.

If you've changed the PCV valve before, it's just above where the PCV is located. The DPFE is almost flat and in a rectangular shape on the top back of the Intake Manifold. It is a little tricky to get to, but nothing to difficult.

Hope this helps, anything else just let us know.

[franzh]

Finally got my sons Explorer back in. Used mirrors, strong lights, finally removed the intake manifold. Sorry, no DPFE here! http://www.automotiveforums.com/vbulletin/#Crying

Bad news is that since I have had the replacement for 6 months, they wont take it back. Further diagnosis showed the problem. Once the manifold was off, I had some room towork.
http://www.automotiveforums.com/vbulletin/#Headshake2

The EGR valve was frozen in the closed position. I took a light hammer and gently persuaded the pintle open, then cleaned around the tip. Got it to work smoothly with vacuum.
This EGR valve has a position sensor and it never showed a movement. Now, still dont know why the code for an incorrect Delta was posted, but all in all, it works now. Took 3 hours to do the manifold R & R and fix the EGR.

Whew.