Ford F150 - EGR Fault P0402

I have a '97 F150 with a 4.6. I have been getting a intermittant CE light, more on than off. Went to Auto Zone to pull the CE code, they came up with P0402 eccesive egr flow. I removed the egr valve and it seems to be functioning correctly when I put a vac on it. Any suggestions where to go from here? I hate CE lights!

Thanks, Airman

Replace the PFE sensor---it's the little rectangular piece that is greyish silver, has two hoses and an electrical connection. It's on the left side of the engine right near the throtle body and is above the fuel rail monted to a metal bracket. If you go to the dealer to get this---might be the only place you can get it---ask for a base part number of a 9J460. They'll know what you want. The new one might look different---it's black plastic but has the same shape and size. Make ure you connect the right hoses to the right ports. One is larger and one is smaller.

Thanks, I'm going to try that.

I have the same problem with engine light and EGR insufficient flow. I cleaned the throttle body and it was completly clogged in the farthest port from the EGR and almost closed at the closest port to EGR. My Check Engine Light is still coming on with the same code after I reset it. I also changed out the EGR valve. Only two more parts left that I know of, the DPFE and the EVR. WHat should I do now?

DPFE probably needs replacing.

I changed the PFE sensor, my light went out. So far so good, 200 miles.

First of all where is this sensor located and how do you change it.

P0402 is almost always a bad DPFE sensor. I had the same problem with my '01 Expy 4.6. The sensor can be in 1 of two places. This is because the upgraded the part throughout the years. First, look on the left side (driver's side) of your throttle body. It will be a silver rectangular box about 4 inches x 6 inches. It is mounted to the throttle body using two bolts on the top side of the sensor. If the part is not there, you will see 2 empty bolts protuding from the throttle body. If this is the case, it means that you have the updated version of this part. It will be located clode to the driver's side firewall. It is much smaller than the original. I'd say about 1 inch x 2 inches. It has a wiring harness on one end and two small tubes protruding from the bottom of it. The tubes are about 1/4 inch diameter. The tubes are attached to rubber hoses that protrude from the exhaust pipe that attaches to the EGR valve. The best this to do it to go to the dealership and buy a new one. They cost about $35.00. This way, you'll have it in hand while searching for it. Once you find it, carefully disconnect the wiring haress then slowly pull the old sensor away from the rubber tubes. Install the new one in the reverse order. Disconnect the battery for a minute or so to reset the computer. Your problem WILL be fixed. Don't spend uncessary time and money on replacing the EGR valve. They do not usually go bad. This should take you longer to find the part than it will to replace it. Took me about 10 minutes. If you send me an email at atsioukl@tampabay.rr.com, I'll send you a picture that shows you where to find the sensor. Good Luck

Thank you guys very much I got this 402 code the other day and by coming here and looking in this forum i saved myself a lot of time and money. The DPFE aka EGR Sensor was indeed the problem.

Thanks again

HOW MUCH IS THAT PART... ANY IDEA?

The sensor was about $95.00 at my local ford dealer.

I have read the posts about replacing the dpfe sensor.....however, upon searching autozone parts, I find two sensors. (1) is the Pressure sensor-egr valve @ $53.99, and (2) is the egr position sensor @ $25.99. which one, or both?
thanks.

Hey Grinno and Collinstech. I haven't seen you guys around in a while. Glad to see you are still there. Have a Happy New Year.

I've got a '96 Taurus wagon. Check this out: I had a 401 code--EGR INsufficient flow--and a Ford-specific P1400 code, "DPFE Sensor Circuit Low Voltage." I replaced the DPFE and cleared both codes. The next day a 402 code appeared--EGR excessive flow! Any theories? It wasn't the backpressure sensor; that was a few hours old!

I to have had this problem and am proud to say that after replacing the DPFE sensor, have not had a problem since.