P0402 Code - Exhaust Gas Recirculation Flow Excessive Detected

[SVT_RS3]

Hello! This is my fist post in the Bronco6G forum - thanks for the add!


I recently purchased a 2021 Outer Banks (2.3L) on April 1st. On the way home from leaving the dealership it threw a CEL. Code P0402 - Exhaust Gas Recirculation Flow Excessive Detected. I searched the forum but didn’t see anyone else that has posted about this issue.

Truck is at 40,000 miles - cleared the code and drove it approx 200 miles before the code returned.

There are no obvious signs of excessive EGR flow - no bucking, surging, stalling, or rough idle. Fuel economy is not great which could be a sign of EGR issues - around 15 MPG - but I’m mainly attributing that to the 37” tires. I do not see any loose connectors or vacuum lines around the EGR or intake. I did fill up with premium fuel - the CEL came on around 20 miles after fill up.

Looking for advice on what you all believe the issue could be or if anyone else has experienced this issue? Just wanting to research some more before I start tackling the issue.

I have purchased a replacement EGR valve, EGR gasket, and Differential Pressure Sensor but have not installed yet.

Side notes in case anyone asks: The dealership that I purchased from (not Ford) is about 1.5 hours away from me and do not seem motivated to fix the issue even though it happened same day - that’s okay with me, I just want to fix the problem. This issue won’t be covered by Ford since the truck is out of the 3yr/36k warranty. It also won’t be covered by the extended warranty I purchased since it is an emission component. Also - when we checked the code with a scanner, the truck had been driven around 10,000 miles and warmed up approximately 251 times since the last CEL was cleared (or battery disconnected) so I do not believe the dealership was aware of this issue - it was likely coincidence. They only had the truck for a day before I purchased it.

Attaching a photo of my Bronco here and the code reader data - thanks again for the add and looking forward to learning more about these trucks in this group!

I just got this code on my BB about a week ago. Just turned 42k. I was told it was the DPFE sensor, and that Ford wants about $600 to replace it. I found the sensor (Motorcraft) at Rock Auto for about $25. I just need to know where it is. I searched through the service manual that was posted on this site and I couldn't find anything. Does anyone know where it is? I haven't ordered anything yet, as the dealer reset the code and so far it hasn't come back, but if it does, I'll try to replace it myself as long as I'm able.

If anyone knows, I'd appreciate the info!

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[Ducati1098]

I just got this code on my BB about a week ago. Just turned 42k. I was told it was the DPFE sensor, and that Ford wants about $600 to replace it. I found the sensor (Motorcraft) at Rock Auto for about $25. I just need to know where it is. I searched through the service manual that was posted on this site and I couldn't find anything. Does anyone know where it is? I haven't ordered anything yet, as the dealer reset the code and so far it hasn't come back, but if it does, I'll try to replace it myself as long as I'm able.

If anyone knows, I'd appreciate the info!

Drivers side, right on top of the intake.

 

[SVT_RS3]

Thank you!! I have a correction however, after reviewing the notes again they said it was the Differential Pressure Sensor. That looks a lot like the part shown in green in the far right side of the pic, according to the image you posted. Safe to assume that's the right one?

 

[Brian_B]

I'm not a parts hound but looks correct to me

I was trying to upload some pics to go with this statement, but I'll have to give you the AI description since either the site is acting up, or my internet sux


Sensor - Ford (JT4Z-9J460-A)
Looks just like what you posted

*edit* - leaving this here for posterities' sake, but beware, I was 100% incorrect.

 

[Ducati1098]

Thank you!! I have a correction however, after reviewing the notes again they said it was the Differential Pressure Sensor. That looks a lot like the part shown in green in the far right side of the pic, according to the image you posted. Safe to assume that's the right one?

That is definitely not correct.
That picture you posted is the back pressure sensor.
The Ford part number for the DPFE (Differential pressure sensor) is KA1Z-5L200-A (or LB5Z-9J433-B if you want the bracket and hoses to come with it)

 

[Jacobpaulk]

Looping back in on this thread -

About a week ago the CEL went away on it's own without resetting. I've driven around 500 miles and filled up twice since then. No CEL as of today. Truck runs and drives like normal. I have a replacement EGR valve, ERG valve gasket, and DFPE in case the light comes back on.

@Ducati1098 - I am cuious about the part you referenced. I am finding a DPFE similar to what @SVT_RS3 found on Ford's website (I purchased a matching part on Rock Auto as well):

The part you mentioned was listed as the Exhaust Gas Recirculation Valve Control Solenoid:

 

[Ducati1098]

Looping back in on this thread -

About a week ago the CEL went away on it's own without resetting. I've driven around 500 miles and filled up twice since then. No CEL as of today. Truck runs and drives like normal. I have a replacement EGR valve, ERG valve gasket, and DFPE in case the light comes back on.

@Ducati1098 - I am cuious about the part you referenced. I am finding a DPFE similar to what @SVT_RS3 found on Ford's website (I purchased a matching part on Rock Auto as well):

The part you mentioned was listed as the Exhaust Gas Recirculation Valve Control Solenoid:

The problem is you’re expecting some random parts websites to have the verbiage correct, and they’re never accurate.

So I’ll attach the actual Ford workshop manual so you can see what each part is really called:

 

[Swainster]

I believe I’m having the same issue on a 2022 BD, has the light resurfaced since it went away? The code is reading EGR and the light is still on for me. It’s my daily driver and my wife’s car just got hit by another car last week does anyone think it’s okay to drive on until we get my wife’s car back?

 

[Bruinsfan]

A blind squirrel found a nut! I too was experiencing an intermittent p0402 error code and I was prepared to install a new Differential Pressure Feedback Exhaust
Gas Recirculation (EGR) Sensor (LB5Z-9J433-B). However, this morning I was scoping out the job and trying to figure out how small my hands have to be when I discovered that one of the hose was loose when I gave it to tug. I reinstalled the hose and I'll see if it pops off again. Fingers crossed that I got lucky.

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